Heterophasic copolymers and sequential polymerization

ABSTRACT

This invention relates to heterophasic copolymers of propylene and an alpha olefin comonomer having a high fill phase content (≥15%), and heterophasic polymerization processes using a single site catalyst system with a support having high average particle size (PS≥30 μm), high surface area (SA≥400 m 2 /g), low pore volume (PV≤2 mL/g), and a mean pore diameter range of 1≤PD≤20 nm.

CROSS REFERENCE TO RELATED APPLICATIONS

This invention is a Divisional of U.S. Ser. No. 14/142,377 filed Apr.29, 2019, which claims priority to and the benefit of U.S. Ser. No.62/171,616, filed Jun. 5, 2015.

FIELD OF THE INVENTION

This invention relates to heterophasic copolymers, e.g., propylenecopolymers, and to sequential polymerization methods.

BACKGROUND OF THE INVENTION

Recently, efforts have been made to prepare heterophasic copolymers,such as an impact copolymer (ICP), using newly developed metallocene(MCN) catalysis technology to capitalize on the benefits such catalystsprovide. Homopolymers prepared with such “single-site” catalysts oftenhave a narrow molecular weight distribution (MWD), low extractables, anda variety of other favorable properties associated therewith, andcopolymers often also have narrow composition distributions.

Unfortunately, common MCN, immobilized on a conventional support coatedwith an activator such as methylalumoxane (MAO), is not able to providecopolymer components with sufficiently high molecular weight and/orrubber loadings under commercially relevant process conditions. Comparedto their Ziegler-Natta (ZN) system catalyzed counterparts, the iPPmatrix of the ICP prepared using MCN has a low porosity, and is unableto hold a sufficiently high rubber content within the iPP matrixrequired for toughness and impact resistance. Also, the MCN-ICP has anMWD that is too narrow to obtain sufficient crystalline, low molecularweight polymer required for stiffness. The formation of rubber in aseparate phase outside the matrix is undesirable, e.g., it can result insevere reactor fouling.

Pore structures in conventional iPP, whether from ZN or MCN systems, areunderstood to be generated from the fast crystallization of lowmolecular weight portions of the polymer that causes volumetricshrinkage during crystallization. Nello Pasquini (Ed.), PolypropyleneHandbook, 2nd Edition, Hanser Publishers, Munich, pp. 78-89 (2005),reports volumetric shrinkage processes only generate low porosities forlimited rubber loadings, e.g., 7% porosity from a conventional ZNcatalyst system, and 16% more is obtained through the treatment of theMgCl₂-supported ZN system via controlled dealcoholation, allowing theiPP matrix to be filled with a rubber content nearing 25 wt %. Cecchin,G. et al., Macromol. Chem. Phys., vol. 202, p. 1987 (2001), report thatthe micromorphologies of catalyst systems based on magnesiumchloride-supported titanium tetrachloride (MgCl₂/TiCl₄) contribute tothe morphology of the polymer granules. However, the rubber content ofsuch an ICP obtained from an in-reactor, one-catalyst system is stillsignificantly lower than the 40 wt % rubber content that can be achievedin a polymer blend ICP, which provides flexibility for the rubbercontent that is sometimes desired.

Accordingly, it has been elusive to balance the toughness and stiffnessof a one-catalyst, sequential polymerization ICP, since on the one hand,the formation of high porosity and high fill rubber loading needed fortoughness requires the presence of a high concentration of hydrogen toform the low molecular weight polymers needed for thefast-crystallization shrinkage, and on the other hand, polymerizationunder these conditions for maximizing porosity detracts from thestiffness of the resulting ICP.

U.S. Pat. No. 5,990,242 approaches this problem by using anethylene/butene (or higher alpha-olefin) copolymer second component,rather than a propylene copolymer, prepared using a hafnocene type MCN.Such hafnium MCNs are generally useful for producing relatively highermolecular weight polymers; however, their activities are typically muchlower than the more commonly used zirconocenes. In any event, the secondcomponent molecular weights and intrinsic viscosities are lower thandesired for good impact strength.

WO 2004/092225 discloses MCN polymerization catalysts supported onsilica having a 10-50 μm particle size (PS), 200-800 m²/g surface area,and 0.9 to 2.1 mL/g pore volume, and shows an example of a 97 μm PS, 643m²/g surface area and 3.2 mL/g pore volume silica (p. 12, Table I,support E (MS3060)) used to obtain iPP (pp. 18-19, Tables V and VI, run21).

EP 1 380 598 discloses certain MCN catalysts supported on silica havinga 2-12 μm PS, 600-850 m²/g surface area, and 0.1 to 0.8 mL/g porevolume, and shows an example of silica having a 6.9 μm PS, 779 m²/gsurface area and 0.23 mL/g pore volume (p. 25, Table 3, Ex. 16) toobtain polyethylene.

EP 1 541 598 discloses certain MCN catalysts supported on silica havinga 2 to 20 μm particle size, 350-850 m²/g surface area, and 0.1 to 0.8mL/g pore volume (p. 4, lines 15-35), and shows an example of a 10.5 μmparticle size, 648 m²/g surface area and 0.51 mL/g pore volume silica(see p. 17, Example 12) for an ethylene polymerization.

EP 1 205 493 describes a 1126 m²/g specific surface area (SA) and 0.8cc/g structural porous volume (small pores only) silica support usedwith an MCN catalyst for ethylene copolymerization (Examples 1, 6, and7).

JP 2003073414 describes a 1 to 200 μm particle size (PS), 500 m²/g ormore SA, and 0.2 to 4.0 mL/g pore volume (PV) silica, but shows examplesof propylene polymerization with certain MCNs where the silica hasparticle sizes of 12 μm and 20 μm.

JP 2012214709 describes 1.0 to 4.0 μm PS, 260 to 1000 m²/g SA, and 0.5to 1.4 mL/g PV silica used to polymerize propylene.

Other references of interest include US 2011/0034649; US 2011/0081817;Madri Smit et al., Journal of Polymer Science: Part A: PolymerChemistry, Vol. 43, pp. 2734-2748 (2005); and “Microspherical SilicaSupports with High Pore Volume for Metallocene Catalysts,” Ron Shinamotoand Thomas J. Pullukat, presented at “Metallocenes Europe '97Dusseldorf, Germany, Apr. 8-9, 1997.

Accordingly, there is need for new catalysts and/or processes thatproduce polypropylene materials that meet the needs for use inparticular applications, such as one or more of: porosity, a goodbalance of stiffness and toughness, and/or other properties needed forhigh impact strength; homopolymers and copolymers with narrow MWD, lowextractables, bimodal MWD, bimodal PSD, narrow composition distribution,and/or other benefits of MCN catalyzed homopolymers and copolymers; highporosity propylene polymers; heterophasic copolymers with a high fillloading of a second polymer component in a first polymer component;preparation of bimodal MWD or PSD heterophasic copolymers in asingle-catalyst, sequential polymerization process; economic productionusing commercial-scale processes and conditions; and combinationsthereof.

SUMMARY OF THE INVENTION

In some embodiments of the invention, bimodal polypropylene andsequential propylene polymerization processes are presented, whichprocess can produce new propylene polymers having the benefits ofmetallocene (MCN) catalyzed polymers in addition to properties desirablefor high impact strength or other applications. Importantly, thesepolymers can be economically produced using commercial-scale processesand conditions.

In one aspect, embodiments of the invention relate to a heterophasicpropylene polymer, e.g., an impact copolymer (ICP), comprising: (1) amatrix phase comprising: at least 50 mol % propylene; a 1% Secantflexural modulus of at least 1000 MPa, determined according to ASTM D790 (A, 1.0 mm/min); less than 200 regio defects per 10,000 propyleneunits, e.g., between greater than 5 and less than 200 regio defects per10,000 propylene units, determined by ¹³C NMR; if a comonomer ispresent, a composition distribution breadth index (CDBI) of 50% or more;and (2) a fill phase at least partially filling pores in the matrixphase, wherein the fill phase comprises at least 15 wt % (alternately atleast 30 wt %) of the heterophasic propylene copolymer, based on thetotal weight of the matrix and fill phases.

In another aspect, embodiments of the invention relate to a process forpolymerization of propylene and a comonomer, which in some embodimentsmay be sequential, comprising: (a) contacting propylene monomer underpolymerization conditions with a catalyst system comprising a singlesite catalyst precursor compound, an activator, and a support comprisingan average particle size (PS) of more than 30 μm, a specific surfacearea (SA) of 400 m²/g or more, a pore volume (PV) of from 0.5 to 2 mL/g,and a mean pore diameter (PD) of from 1 to 20 nm, to form a matrix ofpropylene polymer comprising at least 50 mol % propylene and a porosityof 15% or more, as determined by mercury intrusion porosimetry; and (b)contacting an alpha olefin monomer selected from ethylene, C₃ to C₂₀alpha olefins, or a combination thereof, including at least one alphaolefin other than propylene, with a second catalyst system underpolymerization conditions to form a fill phase for pores of the matrix,wherein the second catalyst system comprises a metallocene catalystprecursor compound, an activator, and a support, and wherein the secondcatalyst system comprises, compositionally, the same or different singlesite catalyst precursor compound as in the first catalyst system, thesame or different activator as in the first catalyst system, the same ordifferent support as in the first catalyst system, or any combinationthereof. In some embodiments, (1) the polymerization of the alpha olefinmonomer in (b) is in the presence of the matrix phase from (a), (2) thepolymerization of the propylene monomer with the first catalyst systemin (a) is in the presence of the fill phase from (b), or (3) acombination thereof. In some embodiments, the contacting in (a)comprises polymerizing the propylene monomer for a time period, A1,optionally increasing a concentration of hydrogen or other chaintermination agent in the polymerization after time period A1 andpolymerizing the propylene in the presence of the hydrogen or otherchain transfer agent for a time period, A2, wherein a time period Aequals the sum of time periods A1 and A2, and the contacting in (b)comprises polymerizing the alpha olefin monomer for a time period, B,after time period A.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is an electron micrograph showing D 150-60 A silica comprisingagglomerated primary particles.

FIG. 2 is an electron micrograph showing PD 13054 silica comprisingagglomerated primary particles.

FIG. 3 is an electron micrograph showing a comparative MS 3050 silica.

FIG. 4 is a graphical representation showing incremental intrusion(mL/g) versus pore size diameter (μm) of the MCN-catalyzed PiPP4produced according to Example 3.

FIG. 5 is a graphical representation showing incremental intrusion(mL/g) versus pore size diameter (μm) of the comparative MCN-catalyzedCiPP2 produced according to Example 3.

FIG. 6 is a graphical representation showing incremental intrusion(mL/g) versus pore size diameter (μm) of comparative Ziegler-Nattacatalyzed CiPP3 produced according to Example 3.

FIG. 7 is a graphical representation showing a typical particle sizedistribution (PSD) of CiPP6 particles produced using a catalystsupported on a comparative silica, showing a PSD from a heat-treatedcatalyst supportation process according to Example 6.

FIG. 8 is a graphical representation showing the PSD of PiPP12 particlesproduced using a supported catalyst prepared from a low temperaturecontrolled process to inhibit support fragmentation according to Example6.

FIG. 9 is a graphical representation showing the PSD of PiPP13 particlesproduced using a supported catalyst prepared through a mediumtemperature treatment to control partial fragmentation of the supportaccording to Example 6.

FIG. 10 is a graphical representation showing the PSD of PiPP14particles produced using supported catalyst prepared through a hightemperature treatment to promote support fragmentation according toExample 6.

FIG. 11 is a plot of the 4D gel permeation chromatograph (GPC-4D) forheterophasic copolymer ICP1 having about 40% ethylene-propylene rubberloading in a porous iPP matrix according to Example 7.

DEFINITIONS

For purposes of this disclosure and the claims appended thereto, the newnumbering scheme for the Periodic Table Groups is used as described inCHEMICAL AND ENGINEERING NEWS, 63(5), p. 27 (1985).

For purposes herein “mean” refers to the statistical mean or average,i.e., the sum of a series of observations or statistical data divided bythe number of observations in the series, and the terms mean and averageare used interchangeably; “median” refers to the middle value in aseries of observed values or statistical data arranged in increasing ordecreasing order, i.e., if the number of observations is odd, the middlevalue, or if the number of observations is even, the arithmetic mean ofthe two middle values.

For purposes herein, the mode, also called peak value or maxima, refersto the value or item occurring most frequently in a series ofobservations or statistical data, i.e., the inflection point. Aninflection point is that point where the second derivative of the curvechanges in sign. For purposes herein, a multimodal distribution is onehaving two or more peaks, i.e., a distribution having a plurality oflocal maxima; a bimodal distribution has two inflection points; and aunimodal distribution has one peak or inflection point.

For purposes herein, particle size (PS) or diameter, and distributionsthereof, are determined by laser diffraction using a MASTERSIZER 3000(range of 1 to 3500 μm) available from Malvern Instruments, Ltd.Worcestershire, England. Average PS refers to the distribution ofparticle volume with respect to particle size. Unless otherwiseindicated expressly or by context, “particle” refers to the overallparticle body or assembly such as an aggregate, agglomerate orencapsulated agglomerate, rather than subunits or parts of the body suchas the “primary particles” in agglomerates or the “elementary particles”in an aggregate.

For purposes herein, the surface area (SA, also called the specificsurface area or BET surface area), pore volume (PV), and mean or averagepore diameter (PD) of catalyst support materials are determined by theBrunauer-Emmett-Teller (BET) method using adsorption-desorption ofnitrogen (temperature of liquid nitrogen: 77 K) with a MICROMERITICSTRISTAR II 3020 instrument after degassing of the powders for 4 hours at350° C. More information regarding the method can be found, for example,in “Characterization of Porous Solids and Powders: Surface Area, PoreSize and Density”, S. Lowell et al., Springer, 2004. PV refers to thetotal PV, including both internal and external PV. Mean PD refers to thedistribution of total PV with respect to PD.

For purposes herein, porosity of polymer particles refers to the volumefraction or percentage of PV within a particle or body comprising askeleton or matrix of the propylene polymer, on the basis of the overallvolume of the particle or body with respect to total volume. Theporosity and median PD of polymer particles are determined using mercuryintrusion porosimetry. Mercury intrusion porosimetry involves placingthe sample in a penetrometer and surrounding the sample with mercury.Mercury is a non-wetting liquid to most materials and resists enteringvoids, doing so only when pressure is applied. The pressure at whichmercury enters a pore is inversely proportional to the size of theopening to the void. As mercury is forced to enter pores within thesample material, it is depleted from a capillary stem reservoirconnected to the sample cup. The incremental volume depleted after eachpressure change is determined by measuring the change in capacity of thestem. This intrusion volume is recorded with the corresponding pressure.Unless otherwise specified, all porosimetry data are obtained usingMICROMERITICS ANALYTICAL SERVICES and/or the AUTOPORE IV 9500 mercuryporosimeter.

The skeleton of the matrix phase of a porous, particulated material inwhich the pores are formed is inclusive of nonpolymeric and/or inorganicinclusion material within the skeleton, e.g., catalyst system materialsincluding support material, active catalyst system particles, catalystsystem residue particles, or a combination thereof. As used herein,“total volume” of a matrix refers to the volume occupied by theparticles comprising the matrix phase, i.e., excluding interstitialspaces between particles but inclusive of interior pore volumes orinternal porosity within the particles. “Internal” or “interior” poresurfaces or volumes refer to pore surfaces and/or volumes defined by thesurfaces inside the particle which cannot be contacted by other similarparticles, as opposed to external surfaces which are surfaces capable ofcontacting another similar particle.

Where the propylene polymer is wholly or partially filled, e.g., in thecontext of the pores containing a fill rubber or fill material otherthan the propylene polymer, the porosity also refers to the fraction ofthe void spaces or pores within the particle or body regardless ofwhether the void spaces or pores are filled or unfilled, i.e., theporosity of the particle or body is calculated by including the volumeof the fill material as void space as if the fill material were notpresent.

For purposes herein, “as determined by mercury intrusion porosimetry”shall also include and encompass “as if determined by mercury intrusionporosimetry,” such as, for example, where the mercury porosimetrytechnique cannot be used, e.g., in the case where the pores are filledwith a non-gaseous material such as a fill phase. In such a case,mercury porosimetry may be employed on a sample of the material obtainedprior to filling the pores with the material or just prior to anotherprocessing step that prevents mercury porosimetry from being employed,or on a sample of the material prepared at the same conditions used inthe process to prepare the material up to a point in time just prior tofilling the pores or just prior to another processing step that preventsmercury porosimetry from being employed.

The term “agglomerate” as used herein refers to a material comprising anassembly, of primary particles held together by adhesion, i.e.,characterized by weak physical interactions such that the particles caneasily be separated by mechanical forces, e.g., particles joinedtogether mainly at corners or edges. The term “primary particles” refersto the smallest, individual disagglomerable units of particles in anagglomerate (without fracturing), and may in turn be an encapsulatedagglomerate, an aggregate or a monolithic particle. Agglomerates aretypically characterized by having an SA not appreciably different fromthat of the primary particles of which it is composed. Silicaagglomerates are prepared commercially, for example, by a spray dryingprocess.

FIGS. 1-2 show examples of encapsulated agglomerates 10, which, as seenin the partially opened particles, are comprised of a plurality ofprimary particles 12. FIG. 1 shows an electron micrograph of D 150-60 Asilica, which appears as generally spherical particles or grains 10,which, as seen in a partially opened particle, are actually agglomeratescomprised of a plurality of substructures or primary particles 12 withinthe outer spherical shell or aggregate surface 14 that partially orwholly encapsulates the agglomerates. Likewise, FIG. 2 is an electronmicrograph of PD 13054, showing interior agglomerates 10 comprised ofaround 5-50 μm primary particles and encapsulating aggregate 14. Theexamples shown are for illustrative purposes only and the sizes of theparticles shown may not be representative of a statistically largersample; the majority of the primary particles in this or othercommercially available silicas may be larger or smaller than the imageillustrated, e.g., 2 μm or smaller, depending on the particular silicaproduction process employed by the manufacturer.

“Aggregates” are an assembly of elementary particles sharing a commoncrystalline structure, e.g., by a sintering or other physico-chemicalprocess such as when the particles grow together. Aggregates aregenerally mechanically unbreakable, and the specific surface area of theaggregate is substantially less than that of the correspondingelementary particles. An “elementary particle” refers to the individualparticles or grains in or from which an aggregate has been assembled.For example, the primary particles in an agglomerate may be elementaryparticles or aggregates of elementary particles. For more information onagglomerates and aggregates, see Walter, D., PrimaryParticles—Agglomerates—Aggregates, in Nanomaterials (ed DeutscheForschungsgemeinschaft), Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim,Germany, doi: 10.1002/9783527673919, pp. 1-24 (2013).

The terms “monolith” or “monolithic” refer to a material formed of asingle mass of material, and include aggregates as well as bulkmaterials without any defined geometry or grain structure. FIG. 3 showsa comparative support MS 3050, comprised of generally sphericalparticles 20 with an entirely aggregated or monolithic core 22, lackingthe agglomerated primary particles and internal pore morphology of theFIG. 1-2 supports.

The terms “capsule” or “encapsulated” or “microencapsulated” are usedinterchangeably herein to refer to an agglomerate in the 1-1000 μm sizerange comprising an exterior surface that is coated or otherwise has aphysical barrier that inhibits disagglomeration of the primary particlesfrom the interior of microencapsulated agglomerate. The barrier orcoating may be an aggregate, for example, of primary and/or elementaryparticles otherwise constituted of the same material as the agglomerate.FIGS. 1-2 show examples of microencapsulated agglomerates 10 comprisedof a plurality of primary particles 12 within an outer aggregate surfaceor shell 14 that partially or wholly encapsulates the agglomerates, inwhich the primary particles may be allowed to disagglomerate byfracturing, breaking, dissolving, chemically degrading or otherwiseremoving all or a portion of the shell 14.

In the case of spray dried, amorphous, hydrated-surface silica as oneexample, the agglomerates 10 may typically have an overall size range of1-300 μm (e.g., 30-200 μm), the primary particles 12 a size range of0.001-50 μm (e.g., 50-400 nm or 1-50 μm), and the elementary particles asize range of 1-400 nm (e.g., 5-40 nm). As used herein, “spray dried”refers to metal oxide such as silica obtained by expanding a sol in sucha manner as to evaporate the liquid from the sol, e.g., by passing thesilica sol through a jet or nozzle with a hot gas.

“Disagglomeration” or “disagglomerating” refers to the degradation of anagglomerate to release free primary particles and/or smaller fragments,which may also include reaction products and/or materials supported on asurface thereof, e.g., activator and/or catalyst precursor compoundssupported thereon. For example, dispersion in a liquid is a typicalprocess by which unencapsulated agglomerates may be disagglomerated.Optionally, disagglomeration may also form smaller agglomerates as theresidues from which one or more primary particles has been releasedand/or as the result of re-agglomeration of free primary particlesand/or smaller fragments.

“Fracturing” as used herein refers to the degradation of monoliths,aggregates, primary particles, shells or the like. “Fragmentation” or“fragmenting” refers collectively to the release of relatively smallerparticles whether by disagglomeration, fracturing, and/or some otherprocess, as the case may be. The term “fragments” is used herein torefer to the smaller particles including residue agglomerates and anynew particles formed from the preceding larger particles resulting fromfragmentation, including agglomerate residues of primary particles, freeprimary particles, fracturing residues whether smaller or larger thanthe primary particles, and including any of such particles with orwithout supportation products thereon or therein. Fragmentation,especially where disagglomeration is a primary mechanism, may occuressentially without the formation of fines, i.e., the formation of lessthan 2 vol % fines, based on the total volume of the agglomerate. Asused herein “fines” generally refers to particles smaller than 0.5 μm.

Fragmentation can occur by the external application of thermal forcessuch as high heat such as during calcination of support particles,and/or the presence of mechanical forces from crushing under compressionor from the impact of moving particles into contact with other particlesand/or onto fixed surfaces, sometimes referred to as “agitationfragmentation.” Fragmentation can also result in some embodiments hereinfrom the insertion, expansion and/or other interaction of materials inconnection with pores of the particles, such as, for example, when MAOis inserted or polymer is formed in the pores, and subunits of thesupport particle are broken off or the support particle otherwiseexpands to force subunits of the particle away from other subunits,e.g., causing a capsule to break open, forcing primary particles awayfrom each other and/or fracturing primary particles, such as may occurduring polymerization or during a heat treatment for catalystpreparation or activation. This latter type of fragmentation is referredto herein as “expansion fragmentation” and/or “expansiondisagglomeration” in the case of disagglomerating particles from anagglomerate, including microencapsulated agglomerates.

For purposes of this specification and the claims appended thereto, whenreferring to polymerizing in the presence of at least X mmol hydrogen orother chain transfer or termination agent (“CTA”) per mole of propylene,the ratio is determined based upon the amounts of hydrogen or otherchain transfer agent and propylene fed into the reactor. A “chaintransfer agent” is hydrogen or an agent capable of hydrocarbyl and/orpolymeryl group exchange between a coordinative polymerization catalystand a metal center of the CTA during polymerization.

Unless otherwise indicated, “catalyst productivity” is a measure of howmany grams of polymer (Pol or P) are produced using a polymerizationcatalyst comprising W g of catalyst (cat), over a period of time of Thours; and may be expressed by the following formula: P/(T×W) andexpressed in units of grams polymer divided by the product of gramscatalyst and time in hours (gPol gcat⁻¹ hr.⁻¹).

Unless otherwise indicated, “conversion” is the amount of monomer thatis converted to polymer product, and is reported as mol % and iscalculated based on the polymer yield and the amount of monomer fed intothe reactor.

Unless otherwise indicated, “catalyst activity” is a measure of howactive the catalyst is and is reported as the mass of product polymer(P) produced per mole of catalyst (cat) transition metal used (kg P/molcat).

An “olefin”, alternatively referred to as “alkene”, is a linear,branched, or cyclic compound of carbon and hydrogen having at least onedouble bond. For the purposes of this invention, ethylene shall beconsidered an α-olefin. An “alkene” group is a linear, branched, orcyclic radical of carbon and hydrogen having at least one double bond.

For purposes of this specification and the claims appended thereto, whena polymer or copolymer is referred to as comprising an olefin, theolefin present in such polymer or copolymer is the polymerized form ofthe olefin. For example, when a copolymer is said to have an “ethylene”content of 35 wt % to 55 wt %, it is understood that the “mer” unit inthe copolymer is derived from ethylene in the polymerization reactionand said derived units are present at 35 wt % to 55 wt %, based upon theweight of the copolymer. A “polymer” has two or more of the same ordifferent mer units. A “homopolymer” is a polymer having mer units thatare the same. A “copolymer” is a polymer having two or more mer unitsthat are different from each other. A “terpolymer” is a polymer havingthree mer units that are different from each other. “Different” as usedto refer to mer units indicates that the mer units differ from eachother by at least one atom or are different isomerically. Accordingly,the definition of copolymer, as used herein, includes terpolymers andthe like.

An “ethylene polymer” or “polyethylene” or “ethylene copolymer” is apolymer or copolymer comprising at least 50 mol % ethylene derivedunits; a “propylene polymer” or “polypropylene” or “propylene copolymer”is a polymer or copolymer comprising at least 50 mol % propylene derivedunits; and so on. The term “polypropylene” is meant to encompassisotactic polypropylene (iPP), defined as having at least 10% or moreisotactic pentads, highly isotactic polypropylene, defined as having 50%or more isotactic pentads, syndiotactic polypropylene (sPP), defined ashaving at 10% or more syndiotactic pentads, homopolymer polypropylene(hPP, also called propylene homopolymer or homopolypropylene), andso-called random copolymer polypropylene (RCP, also called propylenerandom copolymer). Herein, an RCP is specifically defined to be acopolymer of propylene and 1 to 10 wt % of an olefin chosen fromethylene and C₄ to C₈ 1-olefins. Preferably isotactic polymers (such asiPP) have at least 20% (preferably at least 30%, preferably at least40%) isotactic pentads. A polyolefin is “atactic”, also referred to as“amorphous” if it has less than 10% isotactic pentads and syndiotacticpentads.

The terms “ethylene-propylene rubber” or “EP rubber” (EPR) mean acopolymer of ethylene and propylene, and optionally one or more dienemonomer(s), where the ethylene content is from 35 to 85 mol %, the totaldiene content is 0 to 5 mol %, and the balance is propylene with aminimum propylene content of 15 mol %.

The term “hetero-phase” or “heterophasic” refers to the presence of twoor more morphological phases in a composition comprising two or morepolymers, where each phase comprises a different polymer or a differentratio of the polymers as a result of partial or complete immiscibility(i.e., thermodynamic incompatibility). A common example is a morphologyconsisting of a continuous matrix phase and at least one dispersed ordiscontinuous phase. The dispersed phase takes the form of discretedomains (particles) distributed within the matrix (or within other phasedomains, if there are more than two phases). Another example is aco-continuous morphology, where two phases are observed but it isunclear which one is the continuous phase, and which is thediscontinuous phase, e.g., where a matrix phase has generally continuousinternal pores and a fill phase is deposited within the pores, or wherethe fill phase expands within the pores of an initially globular matrixphase to expand the porous matrix globules, corresponding to the polymerinitially formed on or in the support agglomerates, into subglobuleswhich may be partially or wholly separated and/or co-continuous ordispersed within the fill phase, corresponding to the polymer formed onor in the primary particles of the support. For example, a polymerglobule may initially have a matrix phase with a porosity correspondingto the support agglomerates, but a higher fill phase due to expansion ofthe fill phase in interstices between subglobules of the matrix phase.

The presence of multiple phases is determined using microscopytechniques, e.g., optical microscopy, scanning electron microscopy(SEM), or atomic force microscopy (AFM); or by the presence of two glasstransition (Tg) peaks in a dynamic mechanical analysis (DMA) experiment;or by a physical method such as solvent extraction, e.g., xyleneextraction at an elevated temperature to preferential separate onepolymer phase; in the event of disagreement among these methods, DMAperformed according to the procedure set out in US 2008/0045638 at page36, including any references cited therein, shall be used.

A “polypropylene impact copolymer” or simply an “impact copolymer”(ICP), is a combination, typically heterophasic, of crystalline andamorphous polymers, such as, for example, iPP and rubber, which providethe ICP with both stiffness and toughness, i.e., a stiffness greaterthan that of one or more of the amorphous polymer(s) and a toughnessgreater than that of one or more of the crystalline polymer(s). An ICPmay typically have a morphology such that the matrix phase comprises ahigher proportion of the crystalline polymer, and a rubber is present ina lower proportion in a dispersed or co-continuous phase, e.g., a blendcomprising 60 to 95 wt % of a matrix of iPP, and 5 to 40 wt % of anethylene, propylene or other polymer with a T_(g) of −30° C. or less.

The term “sequential polymerization” refers to a polymerization processwherein different polymers are produced at different periods of time inthe same or different reactors, e.g., to produce a multimodal and/orheterophasic polymer. The terms “gas phase polymerization,” “slurryphase polymerization,” “homogeneous polymerization process,” and “bulkpolymerization process” are defined below.

The term “continuous” means a system that operates without interruptionor cessation. For example, a continuous process to produce a polymerwould be one where the reactants are continually introduced into one ormore reactors and polymer product is continually withdrawn.

As used herein, Mn is number average molecular weight, Mw is weightaverage molecular weight, Mz is z average molecular weight, wt % isweight percent, and mol % is mole percent. Molecular weight distribution(MWD), also referred to as polydispersity (PDI), is defined to be Mwdivided by Mn. Unless otherwise noted, all molecular weights (e.g., Mw,Mn, and Mz) are g/mol and are determined by GPC-DRI as described below.The following abbreviations may be used herein: Me is methyl, Et isethyl, Pr is propyl, cPr is cyclopropyl, nPr is n-propyl, iPr isisopropyl, Bu is butyl, nBu is normal butyl, iBu is isobutyl, sBu issec-butyl, tBu is tert-butyl, Oct is octyl, Ph is phenyl, Bn is benzyl,THF or thf is tetrahydrofuran, MAO is methylalumoxane, OTf istrifluoromethanesulfonate.

Ambient temperature, also referred to herein as room temperature (RT),is 23° C.±3° C. unless otherwise indicated.

A “catalyst system” is a combination of at least one catalyst precursorcompound, at least one activator, an optional co-activator, and asupport material. A polymerization catalyst system is a catalyst systemthat can polymerize monomers to polymer. For the purposes of thisinvention and the claims thereto, when catalyst systems are described ascomprising neutral stable forms of the components, it is well understoodby one of ordinary skill in the art that the ionic form of the componentis the form that reacts with the monomers to produce polymers.

In the description herein, the single site catalyst precursor compoundmay be described as a catalyst precursor, a catalyst precursor compound,a pre-catalyst compound, metallocene or MCN, metallocene compound,metallocene catalyst, metallocene catalyst compound, metallocenecatalyst precursor compound or a transition metal compound, or similarvariation, and these terms are used interchangeably. A catalystprecursor compound is a neutral compound without polymerizationactivity, e.g., Cp₂ZrCl₂, which requires an activator, e.g., MAO, toform an active catalyst species, e.g., [Cp₂ZrMe]⁺, or a resting activecatalyst species, e.g., [Cp₂Zr(μ-Me)₂AlMe₂]⁺to become capable ofpolymerizing olefin monomers. A metallocene catalyst is defined as anorganometallic compound (and may sometimes be referred to as such incontext) with at least one π-bound cyclopentadienyl moiety (orsubstituted cyclopentadienyl moiety) and more frequently two π-boundcyclopentadienyl moieties or substituted cyclopentadienyl moieties.Indene, substituted indene, fluorene and substituted fluorene are allsubstituted cyclopentadienyl moieties.

The phrase “compositionally different” means the compositions inquestion differ by at least one atom. For example, cyclopentadienediffers from methyl cyclopentadiene in the presence of the methyl group.For example, “bisindenyl zirconium dichloride” is different from“(indenyl)(2-methylindenyl) zirconium dichloride” which is differentfrom “(indenyl)(2-methylindenyl) hafnium dichloride.” Catalyst compoundsthat differ only by isomer are considered the same for purposes of thisinvention, e.g., rac-dimethylsilylbis(2-methyl 4-phenyl)hafnium dimethylis considered to be the same as meso-dimethylsilylbis(2-methyl4-phenyl)hafnium dimethyl.

An organometallic compound is defined as a compound containing at leastone bond between a carbon atom of an organic compound and a metal, andis typically, although not always, capable of deprotonating hydroxylgroups, e.g., from a support material. A deprotonating agent is definedas a compound or system capable of deprotonating hydroxyl groups fromthe support, and may be an organometallic or another compound such as ametal amide, e.g., aluminum amide or lithium amide.

An “anionic ligand” is a negatively charged ligand, which donates one ormore pairs of electrons to a metal ion. A “neutral donor ligand” is aneutrally charged ligand, which donates one or more pairs of electronsto a metal ion.

The terms “cocatalyst” and “activator” are used herein interchangeablyand are defined to be any compound which can activate the catalystprecursor compound by converting a neutral catalyst precursor compoundto a catalytically active catalyst compound cation. The terms,“non-coordinating anion” (NCA), “compatible” NCA, “bulky activator,”“molecular volume,” “less bulky,” “more bulky,” are defined below.

In embodiments, the heterophasic propylene polymer composition producedherein, e.g., comprising fill rubber, or produced with phased hydrogensupply, and/or produced after time period B when specified, may bereferred to herein as an impact copolymer, or a propylene impactcopolymer, or an in-reactor propylene impact copolymer, or an in-reactorpropylene impact copolymer composition, and such terms are usedinterchangeably herein.

The terms “hydrocarbyl radical”, “hydrocarbyl” and “hydrocarbyl group”are used interchangeably throughout this document. Likewise, the terms“group”, “radical”, and “substituent” are also used interchangeably inthis document. For purposes of this disclosure, “hydrocarbyl radical” isdefined to be a radical, which contains hydrogen atoms and up to 100carbon atoms and which may be linear, branched, or cyclic, and whencyclic, aromatic or non-aromatic.

A substituted hydrocarbyl radical is a hydrocarbyl radical where atleast one hydrogen has been replaced by a heteroatom or heteroatomcontaining group.

Halocarbyl radicals are radicals in which one or more hydrocarbylhydrogen atoms have been substituted with at least one halogen (e.g., F,Cl, Br, I) or halogen-containing group (e.g., CF₃).

Silylcarbyl radicals (also called silylcarbyls) are groups in which thesilyl functionality is bonded directly to the indicated atom or atoms.Examples include SiH₃, SiH₂R*, SiHR*₂, SiR*₃, SiH₂(OR*), SiH(OR*)₂,Si(OR*)₃, SiH₂(NR*₂), SiH(NR*₂)₂, Si(NR*₂)₃, and the like, where R* isindependently a hydrocarbyl or halocarbyl radical and two or more R* mayjoin together to form a substituted or unsubstituted saturated,partially unsaturated or aromatic cyclic or polycyclic ring structure.

Germylcarbyl radicals (also called germylcarbyls) are groups in whichthe germyl functionality is bonded directly to the indicated atom oratoms. Examples include GeH₃, GeH₂R*, GeHR*₂, GeR*₃, GeH₂(OR*),GeH(OR*)₂, Ge(OR*)₃, GeH₂(NR*₂), GeH(NR*₂)₂, Ge(NR*₂)₃, and the like,where R* is independently a hydrocarbyl or halocarbyl radical and two ormore R* may join together to form a substituted or unsubstitutedsaturated, partially unsaturated or aromatic cyclic or polycyclic ringstructure.

Polar radicals or polar groups are groups in which a heteroatomfunctionality is bonded directly to the indicated atom or atoms. Theyinclude heteroatoms of Groups 1-17 of the periodic table either alone orconnected to other elements by covalent or other interactions, such asionic, van der Waals forces, or hydrogen bonding. Examples of functionalgroups include carboxylic acid, acid halide, carboxylic ester,carboxylic salt, carboxylic anhydride, aldehyde and their chalcogen(Group 14) analogues, alcohol and phenol, ether, peroxide andhydroperoxide, carboxylic amide, hydrazide and imide, amidine and othernitrogen analogues of amides, nitrile, amine and imine, azo, nitro,other nitrogen compounds, sulfur acids, selenium acids, thiols,sulfides, sulfoxides, sulfones, sulfonates, phosphines, phosphates,other phosphorus compounds, silanes, boranes, borates, alanes,aluminates. Functional groups may also be taken broadly to includeorganic polymer supports or inorganic support material, such as alumina,and silica. Preferred examples of polar groups include NR*₂, OR*, SeR*,TeR*, PR*₂, AsR*₂, SbR*₂, SR*, BR*₂, SnR*₃, PbR*₃ and the like, where R*is independently a hydrocarbyl, substituted hydrocarbyl, halocarbyl orsubstituted halocarbyl radical as defined above and two R* may jointogether to form a substituted or unsubstituted saturated, partiallyunsaturated or aromatic cyclic or polycyclic ring structure. Alsopreferred are sulfonate radicals, S(═O)₂OR*, where R* is defined asabove. Examples include SO₃Me (mesylate), SO₃(4-tosyl) (tosylate),SO₃CF₃ (triflate), SO₃(n-C₄F₉) (nonaflate), and the like.

An aryl group is defined to be a single or multiple fused ring groupwhere at least one ring is aromatic. Examples of aryl and substitutedaryl groups include phenyl, naphthyl, anthracenyl, methylphenyl,isopropylphenyl, tert-butylphenyl, cyclopropyl, cyclobutyl, cyclopentyl,cyclohexyl, carbazolyl, indolyl, pyrrolyl, and cyclopenta[b]thiopheneyl.Preferred aryl groups include phenyl, benzyl, carbazolyl, naphthyl, andthe like.

In using the terms “substituted cyclopentadienyl”, or “substitutedindenyl”, or “substituted aryl”, the substitution to the aforementionedis on a bondable ring position, and each occurrence is selected fromhydrocarbyl, substituted hydrocarbyl, halocarbyl, substitutedhalocarbyl, silylcarbyl, germylcarbyl, a halogen radical, or a polargroup. A “bondable ring position” is a ring position that is capable ofbearing a substituent or bridging substituent. For example,cyclopenta[b]thienyl has five bondable ring positions (at the carbonatoms) and one non-bondable ring position (the sulfur atom);cyclopenta[b]pyrrolyl has six bondable ring positions (at the carbonatoms and at the nitrogen atom). Thus, in relation to aryl groups, theterm “substituted” indicates that a hydrogen group has been replacedwith a hydrocarbyl, substituted hydrocarbyl, halocarbyl, substitutedhalocarbyl, silylcarbyl, germylcarbyl, a halogen radical, or a polargroup. For example, “methyl phenyl” is a phenyl group having had ahydrogen replaced by a methyl group.

As used herein, “and/or” means either or both (or any or all) of theterms or expressions referred to, and “and or” means the earlier one(s)of the terms or expressions referred to or both (all) of the terms orexpressions referred to, i.e., the later term or expression is optional.

DETAILED DESCRIPTION OF THE INVENTION

The present invention in some embodiments provides a heterophasicpropylene copolymer comprising: (1) a matrix phase comprising: at least50 mol % propylene; a 1% Secant flexural modulus of at least 1000 MPa,determined according to ASTM D 790 (A, 1.0 mm/min); more than 5 and lessthan 200 regio defects per 10,000 propylene units, determined by ¹³CNMR; and if comonomer is present, a composition distribution breadthindex of 50% or more; and (2) a fill phase at least partially fillingpores in the matrix phase, wherein the fill phase comprises at least 15wt % of the heterophasic propylene copolymer, based on the total weightof the matrix and fill phases. In some embodiments, the fill phasecomprises 30 or 35 wt % or more of the heterophasic propylene copolymer,based on the total weight of the matrix and fill phases.

In some embodiments according to the present invention, the matrix phasecomprises a melting point (Tm, DSC peak second melt) of at least 100° C.

In some embodiments according to the present invention, the matrix phasehas a median pore diameter less than 165 μm, as determined by mercuryintrusion porosimetry.

In some embodiments according to the present invention, the fill phasecomprises a polyolefin having a Tg of −20° C. or less determined by DSC.

In some embodiments according to the present invention, the matrix phasehas a multimodal molecular weight distribution and an overall molecularweight distribution of 5 or more.

In some embodiments according to the present invention, the fill phasecomprises ethylene and from about 3 wt % to 75 wt % of one or more C₃ toC₂₀ alpha olefins.

In some embodiments according to the present invention, the fill phasecomprises a CDBI of 50% or more.

In some embodiments according to the present invention, the copolymer isparticulated and at least 95% by volume of the particles has a particlesize greater than about 120 μm.

In some embodiments according to the present invention, the heterophasicpropylene copolymer, further comprises:

-   a. a total propylene content of at least 75 wt %;-   b. a total co-monomer content from about 3 wt % up to about 25 wt %;-   c. a CDBI of at least 60%;-   d. a fill phase content of 35 wt % or more, based on the total    weight of the matrix and fill phases;-   e. a matrix median pore diameter greater than 6 μm and less than 160    μm, as determined by mercury intrusion porosimetry;-   f. at least 50% isotactic pentads;-   g. more than 10 regio defects per 10,000 propylene units, determined    by ¹³C NMR;-   h. a 1% Secant flexural modulus of at least 1800 MPa;-   i. a matrix phase comprising a melting point (Tm, DSC peak second    melt) of at least 120° C.;-   j. a fill phase comprising a Tg of −30° C. or less determined by    DSC;-   k. a heat of fusion (Hf, DSC second heat) of 60 J/g or more;-   l. a multimodal molecular weight distribution, an overall Mw/Mn of    greater than 5 to 20, and at least one mode having an Mw/Mn of    greater than 1 to 5;-   m. at least 95% by volume having a particle size greater than 150 μm    up to 10 mm;-   n. a melt flow rate (MFR, ASTM 1238, 230° C., 2.16 kg) from about    0.1 dg/min up to about 300 dg/min;-   o. an Mw (as measured by GPC-DRI) from 50,000 to 1,000,000 g/mol; or-   p. a combination thereof.

In some embodiments according to the present invention, a process forheterophasic polymerization of propylene and a comonomer comprises: (a)contacting propylene monomer under polymerization conditions with afirst catalyst system, comprising a single site catalyst precursorcompound, an activator, and a support having an average particle size ofmore than 30 microns, a surface area of 400 m²/g or more, a pore volumeof from 0.5 to 2 mL/g, and a mean pore diameter of from 1 to 20 nm (10to 200 angstroms) as determined by BET nitrogen adsorption, to form amatrix phase of propylene polymer comprising at least 50 mol % propyleneand a porosity of 15% or more as determined by mercury intrusionporosimetry; and (b) contacting an alpha olefin monomer selected fromethylene, C₃ to C₂₀ alpha olefins, or a combination thereof, includingat least one alpha olefin other than propylene, with a second catalystsystem under polymerization conditions to form a fill phase for pores ofthe matrix, wherein the second catalyst system comprises a metallocenecatalyst precursor compound, an activator, and a support, and whereinthe second catalyst system comprises, compositionally, the same ordifferent single site catalyst precursor compound as in the firstcatalyst system, the same or different activator as in the firstcatalyst system, the same or different support as in the first catalystsystem, or any combination thereof.

In some embodiments according to the present invention, (1) thepolymerization of the alpha olefin monomer in (b) is in the presence ofthe matrix phase from (a), (2) the polymerization of the propylenemonomer with the first catalyst system in (a) is in the presence of thefill phase from (b), or (3) a combination thereof.

In some embodiments according to the present invention, the contactingin (a) comprises polymerizing the propylene monomer for a time period,A1, optionally increasing a concentration of hydrogen or other chaintermination agent in the polymerization after time period A1 andpolymerizing the propylene in the presence of the hydrogen or otherchain transfer agent for a time period, A2, wherein a time period Aequals the sum of time periods A1 and A2, and the contacting in (b)comprises polymerizing the alpha olefin monomer for a time period, B,after time period A.

In some embodiments according to the present invention, time period A2is greater than zero, wherein time period A1 is at least as long as timeperiod A2, and wherein the concentration of the hydrogen or other chaintransfer agent during time period A2 is at least three times greaterthan the concentration of the hydrogen or other chain transfer agent intime period A1.

In some embodiments according to the present invention, the support ofthe first catalyst system has an average PS of more than 50 μm, SA ofless than 1000 m²/g, or a combination thereof.

In some embodiments according to the present invention, the SA of thesupport of the first catalyst system is more than 650 m²/g and the meanPD is less than 7 nm (70 Å).

In some embodiments according to the present invention, the firstcatalyst system has a bimodal particle size distribution, wherein alarger one of the first catalyst system modes comprises at least about80 vol % and a smaller one of the catalyst system modes comprises atleast about 5 vol %, based on the total volume of the first catalystsystem.

In some embodiments according to the present invention, the SA of thesupport of the first catalyst system is less than 650 m²/g, the mean PDis greater than 7 nm (70 Å), or both.

In some embodiments according to the present invention, the support ofthe first catalyst system comprises agglomerates of primary particles,and the second catalyst system comprises fragments from the firstcatalyst system.

In some embodiments according to the present invention, the alpha olefinmonomer comprises ethylene and from about 3 wt % to 75 wt % of one ormore C₃ to C₂₀ alpha olefins.

In some embodiments according to the present invention, the propylenemonomer in (a) is essentially free of ethylene and C₄ to C₂₀ alphaolefins, and the propylene polymer formed after time period A is apropylene homopolymer.

In some embodiments according to the present invention, the activator ofthe first catalyst system comprises alumoxane.

In some embodiments according to the present invention, the firstcatalyst system further comprises a co-activator selected from the groupconsisting of: trialkylaluminum, dialkylmagnesium, alkylmagnesiumhalide, and dialkylzinc.

In some embodiments according to the present invention, the contactingof the propylene monomer with the first catalyst system during timeperiod A1, time period A2, or the contacting of the alpha olefin monomerwith the second catalyst system during time period B, or a combinationthereof, are carried out in the liquid slurry phase.

In some embodiments according to the present invention, thepolymerization conditions during time periods A1, A2, and B comprise apressure of from about 0.96 MPa (140 psi) to about 5.2 MPa (750 psi) anda temperature of from about 50° C. to 100° C.

In some embodiments according to the present invention, the processfurther comprising melt processing the propylene polymer at a shear rateof 1000 s⁻¹ or more.

Preferred embodiments of the catalyst system, support, activator,catalyst precursor compound, and co-activator are described in moredetail below.

Support Materials: In embodiments according to the invention herein, thecatalyst system may comprise porous solid particles as an inert supportmaterial to which the catalyst precursor compound and/or activator maybe anchored, bound, adsorbed or the like. Preferably, the supportmaterial is an inorganic oxide in a finely divided form. Suitableinorganic oxide materials for use in MCN catalyst systems herein includeGroups 2, 4, 13, and 14 metal oxides, such as silica, alumina, magnesia,titania, zirconia, and the like, and mixtures thereof. Other suitablesupport materials, however, can be employed, for example, finely dividedfunctionalized polyolefins, such as finely divided polyethylene orpolypropylene. Particularly useful supports include silica, magnesia,titania, zirconia, montmorillonite, phyllosilicate, zeolites, talc,clays, and the like. Also, combinations of these support materials maybe used, for example, silica-chromium, silica-alumina, silica-titania,and the like.

In some preferred embodiments, the support material preferably comprisessilica, e.g., amorphous silica, which may include a hydrated surfacepresenting hydroxyl or other groups which can be deprotonated to formreactive sites to anchor activators and/or catalyst precursors. Otherporous support materials may optionally be present with the preferredsilica as a co-support, for example, talc, other inorganic oxides,zeolites, clays, organoclays, or any other organic or inorganic supportmaterial and the like, or mixtures thereof.

The support materials of some embodiments of the invention,unexpectedly, are generally resistant to agitation fragmentation orexpansion fragmentation during calcination temperatures. In someembodiments, the support can be calcined essentially free offragmentation, i.e., the PS distribution is not changed significantlyand/or less than 5 vol % of primary particles (if present) and/or finesis generated, by total volume of the support material.

According to some embodiments of the invention, the support material isthen contacted with the activator (described in more detail below), atleast one single site catalyst precursor compound (described in moredetail below), and/or cocatalyst (described in more detail below), andoptionally a scavenger or co-activator (described in more detail below).

According to some embodiments of the invention, the support in, and/orused to prepare, the catalyst system, preferably has or comprises thefollowing:

-   a) an average particle size (PS) and/or a PS mode of more than 30    μm, or more than 40 μm, or more than 50 μm, or more than 60 μm, or    more than 65 μm, or more than 70 μm, or more than 75 μm, or more    than 80 μm, or more than 85 μm, or more than 90 μm, or more than 100    μm, or more than 120 μm; and/or up to 200 μm, or less than 180 μm,    or less than 160 μm, or less than 150 μm, or less than 130 μm; e.g.,    30-200 μm, or 50-200 μm, or 60-200 μm;-   b) a pore volume (PV) from at least 0.1 mL/g, or at least 0.15 mL/g,    or at least 0.2 mL/g, or at least 0.25 mL/g, or at least 0.3 mL/g,    or at least 0.5 mL/g; and/or up to 2 mL/g, or less than 1.6 mL/g, or    less than 1.5 mL/g, or less than 1.4 mL/g, or less than 1.3 mL/g;    e.g., 0.5-2 mL/g, or 0.5-1.5 mL/g, or 1.1-1.6 mL/g;-   c) a specific surface area (SA) of less than 1400 m²/g, or less than    1200 m²/g, or less than 1100 m²/g, or less than 1000 m²/g, or less    than 900 m²/g, or less than 850 m²/g, or less than 800 m²/g, or less    than 750 m²/g, or less than 700 m²/g, or less than 650 m²/g; and/or    more than 400 m²/g, or more than 600 m²/g, or more than 650 m²/g, or    more than 700 m²/g; e.g., 400-1000 m²/g, or 600-1000 m²/g, or    650-1000 m²/g, or 700-1000 m²/g, or 400-650 m²/g, or 400-700 m²/g;-   d) a mean pore diameter (PD) greater than 0.1 nm, greater than 1 nm,    or greater than 2 nm, or greater than 3 nm, or greater than 4 nm, or    greater than 5 nm, or greater than 6 nm, or greater than 7 nm, or    greater than 8 nm; and/or less than 20 nm, or less than 15 nm, or    less than 13 nm, or less than 12 nm, or less than 10 nm, or less    than 8 nm, or less than 7 nm, or less than 6 nm; e.g., 1-7 nm, or    1-8 nm, or 1-13 nm, or 7-13 nm, or 8-13 nm, or 7-20 nm, or 8-20 nm;-   e) agglomerates composed of a plurality of primary particles, the    primary particles having an average PS of 1 nm to less than 50 μm,    or 1 μm to less than 30 μm;-   f) microencapsulated agglomerates;-   g) spray dried;-   h) silica, e.g., amorphous silica and/or silica having a hydrated    surface; and/or-   i) any combination or subcombination thereof.

In some embodiments, the support comprises an agglomerate of a pluralityof primary particles, and in further embodiments the support is at leastpartially encapsulated. Additionally or alternatively, the supportcomprises a spray dried material, e.g., spray dried silica. Inembodiments according to the present invention, the support materials,in addition to meeting the PS, SA, PV, and PD characteristics, arepreferably made from a process that agglomerates smaller primaryparticles, e.g., average PS in the range of 0.001-50 μm, into the largeragglomerates with average PS in the range of 30-200 μm, such as thosefrom a spray drying process. The larger particles, i.e., theagglomerates, may thus comprise small particles, i.e., primaryparticles. Either or both of the agglomerates and/or primary particlescan have high or low sphericity and roundness, e.g., a Wadell sphericityof 0.8 or more, 0.85 or more, 0.9 or more, or 0.95 or more, or less than0.95, less than 0.90, less than 0.85, or less than 0.8; and a Wadellroundness from 0.1 or less, up to 0.9 or more.

The SA, PV, and mean PD, are generally interrelated, in someembodiments, in that within certain ranges of these parameters theproduct of the mean PD and SA may be proportional to the PV. The PV, PD,and SA in some embodiments are preferably selected to balance thedesired mechanical strength with the desired activator loading, i.e.,high SA to accommodate high activator and catalyst loading, yet not toohigh so as to maintain sufficient strength to avoid fragmentation duringcalcination or from agitation and handling, while at the same timeavoiding excessive strength, which might undesirably inhibitfragmentation during polymerization in some embodiments. Preferably, tomeet these requirements the support materials in some embodiments of theinvention have PS in the range of 30-200 μm, SA 400-1000 m²/g, PV 0.5-2mL/g, and mean PD 1-20 nm. Silicas which may be suitable according tosome embodiments of the invention are commercially available under thetrade designations D 150-60 A, D 100-100 A, D 70-120, PD 13054, PD14024, and the like. This combination of property ranges is in contrastto most other silica supports used for MCN catalysts for iPP. Forexample, if the SA is too low, the activity may be low; if the PV is toohigh, the particles may be mechanically fragile; if the PS and/or PV aretoo small, the result may be low activity, low porosity, low rubberfill, excess surface-deposited rubber, and/or reactor fouling; and ifthe PS is too large, heat removal is inefficient, monomer mobility intothe interior of the polymer particle is limited, monomer concentrationis insufficient, chain termination is premature, and/or low molecularweights result.

In some embodiments, agglomerates having, within the preferred ranges ofSA≥400 m²/g and mean PD=1-20 nm, either a lower SA, e.g., less than 700m²/g or less than 650 m²/g, and/or a higher mean PD, e.g., more than 7nm or more than 8 nm, have higher strength and are more resistant todebris dominated fragmentation during the supportation process, whichcan thus be carried out at higher temperatures, and higher catalystloadings can be achieved for higher catalyst activity.

In some other embodiments, on the other hand, agglomerates with SAgreater than 650 m²/g or greater than 700 m²/g, and mean PD less than 8nm or less than 7 nm, can be prepared with minimal fragmentation withcarefully controlled process conditions such as low supportationreaction temperatures, and yet may more readily fragment duringpolymerization, which can lead to relatively higher propylene polymerporosity and/or higher fill phase content in the case of heterophasiccopolymers. On the other hand, when SA is in the range of about 650 or700 m²/g or higher, to maintain mechanical strength the PD must be low,e.g., less than 7 nm, and the silica fragmentation can be promoted, ifdesired, using supportation conditions that facilitate the essentiallycomplete or partial fragmentation, e.g., at a temperature higher thanabout 40 or 60° C.

According to some embodiments of the invention, the support material mayfurther comprise, in addition to or in combination with any one or moreof the support materials or supported catalyst systems or mixturesdescribed above, an optional second or co-support material, which may bedesigned to promote the polymerization of another propylene polymer orcopolymer (as in a bimodal polypropylene) and/or another olefin polymeror copolymer, e.g., a rubber fill material or an EP rubber (as in animpact copolymer). The second catalyst support material according tosome embodiments of the invention, when present, is most preferably aninorganic oxide, has SA in the range of from about 10 to about 700 m²/g,PV in the range of from about 0.1 to about 4.0 mL/g, and average PS inthe range of from about 5 to about 500 μm. More preferably, the SA ofthe second catalyst support material is in the range of from about 50 toabout 500 m²/g, PV of from about 0.5 to about 3.5 mL/g and average PS offrom about 10 to about 200 μm. Most preferably the SA of the secondcatalyst support material is in the range is from about 100 to about 400m²/g, PV from about 0.8 to about 3.0 mL/g and average PS is from about 5to about 100 μm. The mean PD of the second catalyst support materialuseful in some embodiments of the invention is in the range of from 1 to100 nm (10 to 1000 Å), preferably 5 to 50 nm (50 to about 500 Å), andmost preferably 7.5 to 35 nm (75 to about 350 Å). In some embodiments ofthe invention, the second catalyst support material is a high SA,amorphous silica (surface area=300 m²/gm; pore volume of 1.65 mL/gm).Preferred second support silicas, when present, are marketed under thetradenames listed in Table A, especially GRACE 952 (also known asDAVISON 952) or GRACE 955 (also known as DAVISON 955) by the DavisonChemical Division of W.R. Grace and Company, and in other embodimentsGRACE 948 (also known as DAVISON 948) second support is used.

The support material can be used wet, i.e., containing adsorbed water,or dry, that is, free of absorbed water. The amount of absorbed watercan be determined by standard analytical methods, e.g., LOD (loss ofdrying) from an instrument such as LECO TGA 701 under conditions such as300° C. for 3 hours. In some embodiments of the invention, wet supportmaterial (without calcining) can be contacted with the activator oranother organometallic compound as otherwise described below, with theaddition of additional organometallic or other scavenger compound thatcan react with or otherwise remove the water, such as a metal alkyl. Forexample, contacting wet silica with an aluminum alkyl such as AlMe₃,usually diluted in an organic solvent such as toluene, forms in-situMAO, and if desired additional MAO can be added to control the desiredamount of MAO loaded on the support, in a manner otherwise similar asdescribed below for dry silica.

Drying of the support material can be effected according to someembodiments of the invention by heating or calcining above about 100°C., e.g., from about 100° C. to about 1000° C., preferably at leastabout 200° C. When the support material is silica, according to someembodiments of the invention it is heated to at least 130° C.,preferably about 130° C. to about 850° C., and most preferably at about200-600° C.; and for a time of 1 minute to about 100 hours, e.g., fromabout 12 hours to about 72 hours, or from about 24 hours to about 60hours. The calcined support material in some embodiments according tothis invention, comprises at least some groups reactive with anorganometallic compound, e.g., reactive hydroxyl (OH) groups to producethe supported catalyst systems of this invention.

Supportation: According to some embodiments of the invention, thesupport is treated with an organometallic compound to react withdeprotonated reactive sites on the support surface. In general thesupport is treated first with an organometallic activator such as MAO,and then the supported activator is treated with the MCN, optional metalalkyl co-activator, as in the following discussion for illustrativepurposes, although the MCN and or co-activator can be loaded first,followed by contact with the other catalyst system components,especially where the activator is not an organometallic compound orotherwise reactive with the support surface.

The support material in some embodiments, having reactive surfacegroups, typically hydroxyl groups, e.g., after calcining (or metal alkyltreatment, e.g., in the wet process), is slurried in a non-polar solventand contacted with the organometallic compound (activator in thisexample), preferably dissolved in the solvent, preferably for a periodof time in the range of from about 0.5 hours to about 24 hours, fromabout 2 hours to about 16 hours, or from about 4 hours to about 8 hours.Suitable non-polar solvents are materials in which, other than thesupport material and its adducts, all of the reactants used herein,i.e., the activator, and the MCN compound, are at least partiallysoluble and which are liquid at reaction temperatures. Preferrednon-polar solvents are alkanes, such as isopentane, hexane, n-heptane,octane, nonane, and decane, although a variety of other materialsincluding cycloalkanes, such as cyclohexane, aromatics, such as benzene,toluene, and ethylbenzene, may also be employed.

The mixture of the support material and activator (or otherorganometallic compound) in various embodiments of the invention maygenerally be heated or maintained at a temperature of from about −60° C.up to about 130 or 140° C., such as, for example: about 40° C. or below,about 23° C. or below, about −20° C. or below; from about 10° C. or 20°C. up to about 60° C. or about 40° C.; 23° C. or about 25° C. or above;or from about 40° C., about 60° C., or about 80° C. up to about 100° C.,or about 120° C. Where the support may be susceptible to fragmentationduring activator/catalyst precursor supportation (e.g., SA≥650 m²/g,PD≤7 nm), fragmentation can be controlled through the manipulation ofreaction conditions to inhibit fragmentation such as at a lower reactiontemperature, e.g., −60-40° C., preferably −20° C.-30° C., to achieve <10vol % fragmented particles, preferably <5 vol % fragmented particles; orto promote fragmentation such as at a higher reaction temperature, e.g.,≥40° C., preferably ≥60° C., to achieve >10 vol % fragmented particles,e.g., 10-80 vol % fragmented particles, such as 10-20 vol % fragmentedparticles, 20-70 vol % fragmented particles, 70-90 vol % fragmentedparticles, >90 vol % fragmented particles, or the like. In general, thetime and temperature required to promote fragmentation are inverselyrelated, i.e., at a higher temperature, debris dominated fragmentationmay require a shorter period of time.

According to some embodiments of the present invention, the supportmaterial is not fragmented during supportation or other treatment priorto polymerization, i.e., the supported catalyst system has a PSD that isessentially maintained upon treatment with the organometallic compoundand/or less than 5 vol % of fines is generated by volume of the totalsupport material, e.g., where the support material is resistant tofragmentation, or supportation conditions are selected to inhibitfragmentation.

Maintaining a sufficiently large average PS or PS mode of the supportedcatalyst system material, according to some embodiments of theinvention, facilitates the formation of sufficiently large propylenepolymer particles rich with small pores, which can, for example, bereadily filled with rubber fill, e.g., in making an ICP or otherheterophasic copolymer. On the other hand, an excess of porouspolypropylene fines, e.g., 5 vol % or more smaller than 120 μm,generally formed from smaller particles such as the primary particles ofthe support material agglomerates or sub-primary particle debris orfines, may result in fouling or plugging of the reactor, lines orequipment during the polymerization of a rubber in the presence of theporous polypropylene or vice versa, and/or in the formation ofnon-particulated polymer.

In embodiments according to the present invention, the supportedcatalysts, e.g., on silica with SA>about 650 m²/g and PD<about 70 Å, areable to polymerize propylene to produce iPP resins with very highstiffness, e.g., up to 2200 MPa 1% secant flexural modulus. In someembodiments according to the present invention, the supported catalysts,e.g., on silica with balanced PS, SA, PV, and PD, such as, for example,PS 70-100 μm, SA 400-650 m²/g, PV 1.1-1.6 mL/g, and PD 90-120 Å, andprepared under low fragmentation conditions, are able to polymerizepropylene to produce iPP resins, and/or having relatively high porosity,e.g., greater than 30%. Furthermore, highly porous structures can houseactive catalytic species to continue polymerizing additional monomers toform second phase copolymers in heterophasic copolymers such as ICP withimproved physical/chemical properties. ICP resins prepared from thecatalysts based on MAO supported on support materials with limitedfragmentation as disclosed herein have been discovered to show improvedethylene-propylene (EP) rubber uptake.

In contrast to known catalyst support materials which may have aconventional unimodal distribution of particle sizes, the mixtures offinished catalyst supported on fragmented and non-fragmented supports,according to some embodiments of the invention are bimodal in PSD, anddifferent polypropylene properties are thereby achieved, and with theresult that the different polypropylene properties can be balanced asdesired. Additionally, in some embodiments, the PSD of the resulting iPPresin changes according to the PSD of the supported catalyst system,i.e., support fragments produce smaller iPP particles relative to thelarger iPP particles formed from the larger more or less intactagglomerates. In general, in the context of propylene polymerizationaccording to various embodiments of the present invention, thenon-fragmented support particles facilitate the formation of large PS,high PV, low PD, fillable polypropylene particles, whereas the fragmentsmay facilitate a higher catalyst activity and formation of apolypropylene with smaller PS and higher stiffness, and thus theporosity, rubber fill content and stiffness can be balanced by selectingthe appropriate mix of fragmented and non-fragmented supports.

With reference to FIG. 7, CiPP6 obtained in Example 6 using aconventional catalyst with a relatively broad, unimodal PSD has acorresponding bell-shaped curve. With reference to FIGS. 8-10 andExample 6, the finished catalyst, supported on non-fragmentedagglomerates obtains a PSD in the relatively large-size area of PiPP12(FIG. 8), supported on a mix of non-fragmented agglomerates andfragments gives a bimodal distribution of both large and small PiPP13particles (FIG. 9), and supported on debris dominated fragments obtainsa small particle size dominated bell-shaped distribution of PiPP14 (FIG.10). In FIG. 8, the PSD of PiPP12 from the catalyst prepared underreaction conditions of −20-0° C. for 3 hours shows the majority as largeparticles from non-fragmented catalyst particles; in FIG. 9, the PSD ofthe PiPP13 from the catalyst prepared under reaction conditions of 80°C. for 1 hour shows two modes, i.e., a smaller, second mode from thecatalyst system fragments; and in FIG. 10 the PSD of PiPP14 from thecatalyst prepared under reaction conditions of 100° C. for 3 hours showsthe majority as relatively small particles from the catalyst systemfragments. Further, porosity analyses based on oil filling microscopyindicated that the small-particle iPP mode has low porosity, e.g., 2 vol%, whereas the large-particle iPP mode has high porosity, e.g., 40 vol%. Therefore, such supports prepared with low temperature treatment orother mild reaction conditions, according to these examples, avoidscatalyst fragmentation and provides very high rubber loadings, e.g., upto 76 wt % or more, without significant reactor fouling.

For the first time, high porosity iPP resins may be formed based on thesupport structure, independent of polymerization conditions utilized byother systems to gain iPP porosity, e.g., other systems that polymerizepropylene under high hydrogen polymerization conditions to produce lowmolecular weight resins that crystallize and shrink to form limitedpores. High stiffness and high porosity iPP resins according to theinstant disclosure can be obtained, in some embodiments, regardless ofthe hydrogen concentration in the polymerization, and result in improvedICP.

In some embodiments of the invention, the catalyst system has amultimodal PSD, e.g., a bimodal PSD comprising relatively large andsmall particle size modes, wherein the large particle size modecomprises at least about 80 vol % and the low molecular weight modecomprises at least about 1 vol % (alternately at least about 2 vol %, atleast about 3 vol %, at least about 5 vol %), based on the total volumeof the catalyst system.

In some embodiments of the invention, the supported activator isoptionally treated with another organometallic compound which is alsoselected as the scavenger, preferably a metal alkyl such as an aluminumalkyl, to scavenge any hydroxyl or other reactive species that may beexposed by or otherwise remaining after treatment with the firstorganometallic compound, e.g., hydroxyl groups on surfaces exposed byfragmentation may be reacted and thereby removed by contact of thefragments with an aluminum alkyl such as triisobutylaluminum (TIBA).Useful metal alkyls which may be used according to some embodiments ofthe invention to treat the support material have the general formulaR_(n)-M, wherein R is C₁-C₄₀ hydrocarbyl such as C₁-C₁₂ alkyl forexample, M is a metal, and n is equal to the valence of M, and mayinclude oxophilic species such as diethyl zinc and aluminum alkyls, suchas, for example, trimethylaluminum, triethylaluminum,triisobutylaluminum, tri-n-hexylaluminum, tri-n-octylaluminum and thelike, including combinations thereof. Then the activator/supportmaterial is contacted with a solution of the catalyst precursorcompound. In some embodiments of the invention, the supported activatoris generated in situ. In alternate embodiments of the invention, theslurry of the support material is first contacted with the catalystprecursor compound for a period of time in the range of from about 0.5hours to about 24 hours, from about 2 hours to about 16 hours, or fromabout 4 hours to about 8 hours, and the slurry of the supported MCNcompound is then contacted with an organometallic-activator solutionand/or organometallic-scavenger solution.

Activators: Activators are compounds used to activate any one of thecatalyst precursor compounds described above by converting the neutralcatalyst precursor compound to a catalytically active catalyst compoundcation. Non-limiting activators, for example, include alumoxanes,aluminum alkyls, ionizing activators, which may be neutral or ionic, andconventional-type cocatalysts. Preferred activators typically includealumoxane compounds, including modified alumoxane compounds, andionizing anion precursor compounds that abstract a reactive, σ-bound,metal ligand making the metal complex cationic and providing acharge-balancing noncoordinating or weakly coordinating anion.

Alumoxanes are generally oligomeric, partially hydrolyzed aluminum alkylcompounds containing —Al(R1)-O— sub-units, where R1 is an alkyl group,and may be produced by the hydrolysis of the respective trialkylaluminumcompound. Examples of alumoxane activators include methylalumoxane(MAO), ethylalumoxane, butylalumoxane, isobutylalumoxane, modified MAO(MMAO), halogenated MAO where the MAO may be halogenated before or afterMAO supportation, dialkylaluminum cation enhanced MAO, surface bulkygroup modified MAO, and the like. MMAO may be produced by the hydrolysisof trimethylaluminum and a higher trialkylaluminum such astriisobutylaluminum Mixtures of different alumoxanes may also be used asthe activator(s).

There are a variety of methods for preparing alumoxanes suitable for usein the present invention, non-limiting examples of which are describedin U.S. Pat. Nos. 4,665,208; 4,952,540; 5,041,584; 5,091,352; 5,206,199;5,204,419; 4,874,734; 4,924,018; 4,908,463; 4,968,827; 5,308,815;5,329,032; 5,248,801; 5,235,081; 5,157,137; 5,103,031; 5,391,793;5,391,529; 5,693,838; 5,731,253; 5,731,451; 5,744,656; 5,847,177;5,854,166; 5,856,256; 5,939,346; EP 0 561 476; EP 0 279 586; EP 0594-218; EP 0 586 665; WO 94/10180; WO 99/15534; halogenated MAO aredescribed in U.S. Pat. Nos. 7,960,488; 7,355,058; 8,354,485;dialkylaluminum cation enhanced MAO are described in US 2013/0345376;and surface bulky group modified supported MAO are described in U.S.Pat. No. 8,895,465; all of which are herein fully incorporated byreference.

When the activator is an alumoxane, some embodiments select the maximumamount of activator at a 5000-fold molar excess Al/M over the catalystprecursor compound (per metal catalytic site). The minimumactivator-to-catalyst-compound is a 1:1 molar ratio. Alternate preferredranges include from 1:1 to 500:1, alternately from 1:1 to 200:1,alternately from 1:1 to 100:1, or alternately from 1:1 to 50:1, e.g.,1:1 to 10:1 or 10:1 to 50:1.

In an alternate embodiment, little or no alumoxane is used in thepolymerization processes described herein. Preferably, alumoxane ispresent at zero mole %, alternately the alumoxane is present at a molarratio of aluminum to catalyst precursor compound transition metal lessthan 500:1, or less than 300:1, or less than 100:1, or less than 1:1.

It is within the scope of this invention to use an ionizing orstoichiometric activator, neutral or ionic, such as tri(n-butyl)ammonium tetrakis(pentafluorophenyl) borate, a tris perfluorophenylboron metalloid precursor or a tris perfluoronaphthyl boron metalloidprecursor, polyhalogenated heteroborane anions (WO 98/43983), boric acid(U.S. Pat. No. 5,942,459), or combination thereof. It is also within thescope of this invention to use neutral or ionic activators ornon-coordinating anion activators alone or in combination with alumoxaneactivators such as in U.S. Pat. Nos. 8,501,655; 7,897,707; 7,928,172;5,153,157; 5,453,410; EP 0 573 120; WO 94/07928; and WO 95/14044; whichare herein fully incorporated by reference. Further informationregarding ionizing and stoichiometric activators may be found in U.S.Pat. Nos. 8,283,428; 5,153,157; 5,198,401; 5,066,741; 5,206,197;5,241,025; 5,384,299; 5,502,124; 5,447,895; 7,297,653; 7,799,879; WO96/04319; EP 0 570 982; EP 0 520 732; EP 0 495 375; EP 0 500 944; EP 0277 003; EP 0 277 004; EP 0 277 003; and EP 0 277 004; all of which areherein fully incorporated by reference.

Optional Scavengers or Co-Activators: In addition to the activatorcompounds, scavengers or co-activators may be used. Suitableco-activators may be selected from the group consisting of:trialkylaluminum, dialkylmagnesium, alkylmagnesium halide, anddialkylzinc. Aluminum alkyl or organoaluminum compounds which may beutilized as scavengers or co-activators include, for example,trimethylaluminum, triethylaluminum, triisobutylaluminum,tri-n-hexylaluminum, tri-n-octylaluminum, and the like. Other oxophilicspecies, such as diethyl zinc may be used. As mentioned above, theorganometallic compound used to treat the calcined support material maybe a scavenger or co-activator, or may be the same as or different fromthe scavenger or co-activator. In an embodiment, the co-activator isselected from the group consisting of: trimethylaluminum,triethylaluminum, triisobutylaluminum, tri-n-octylaluminum,trihexylaluminum, and diethylzinc (alternately the group consisting of:trimethylaluminum, triethylaluminum, triisobutylaluminum,trihexylaluminum, tri-n-octylaluminum, dimethylmagnesium,diethylmagnesium, dipropylmagnesium, diisopropylmagnesium, dibutylmagnesium, diisobutylmagnesium, dihexylmagnesium, dioctylmagnesium,methylmagnesium chloride, ethylmagnesium chloride, propylmagnesiumchloride, isopropylmagnesium chloride, butyl magnesium chloride,isobutylmagnesium chloride, hexylmagnesium chloride, octylmagnesiumchloride, methylmagnesium fluoride, ethylmagnesium fluoride,propylmagnesium fluoride, isopropylmagnesium fluoride, butyl magnesiumfluoride, isobutylmagnesium fluoride, hexylmagnesium fluoride,octylmagnesium fluoride, dimethylzinc, diethylzic, dipropylzinc, anddibutylzinc).

Metallocene Catalyst Precursor Compounds: According to some embodimentsof the invention, the single site catalyst precursor compound isrepresented by the following formula: (Cp)_(m)R^(A) _(n)M⁴Q_(k); whereineach Cp is a cyclopentadienyl moiety or a substituted cyclopentadienylmoiety substituted by one or more hydrocarbyl radicals having from 1 to20 carbon atoms; R^(A) is a structural bridge between two Cp rings; M⁴is a transition metal selected from groups 4 or 5; Q is a hydride or ahydrocarbyl group having from 1 to 20 carbon atoms or an alkenyl grouphaving from 2 to 20 carbon atoms, or a halogen; m is 1, 2, or 3, withthe proviso that if m is 2 or 3, each Cp may be the same or different; nis 0 or 1, with the proviso that n=0 if m=1; and k is such that k+m isequal to the oxidation state of M⁴, with the proviso that if k isgreater than 1, each Q may be the same or different.

According to some embodiments of the invention, the single site catalystprecursor compound is represented by the formula:R^(A)(CpR″_(p))(CpR*_(q))M⁵Q_(r); wherein each Cp is a cyclopentadienylmoiety or substituted cyclopentadienyl moiety; each R* and R″ is ahydrocarbyl group having from 1 to 20 carbon atoms and may the same ordifferent; p is 0, 1, 2, 3, or 4; q is 1, 2, 3, or 4; R^(A) is astructural bridge between the Cp rings imparting stereorigidity to themetallocene compound; M⁵ is a group 4, 5, or 6 metal; Q is a hydrocarbylradical having 1 to 20 carbon atoms or is a halogen; r is s minus 2,where s is the valence of M⁵; wherein (CpR*_(q)) has bilateral orpseudobilateral symmetry; R*_(q) is an alkyl substituted indenylradical, or tetra-, tri-, or dialkyl substituted cyclopentadienylradical; and (CpR″_(p)) contains a bulky group in one and only one ofthe distal positions; wherein the bulky group is of the formula AR^(W)_(V); and where A is chosen from group 4 metals, oxygen, or nitrogen,and R^(W) is a methyl radical or phenyl radical, and v is the valence ofA minus 1.

According to some embodiments of the invention, the single site catalystprecursor compound is represented by the formula:

where M is a group 4, 5, or 6 metal; T is a bridging group; each X is,independently, an anionic leaving group; each R², R³, R⁴, R⁵, R⁶, R⁷,R⁸, R⁹, R¹⁰, R¹¹, R¹², and R¹³ is, independently, halogen atom,hydrogen, hydrocarbyl, substituted hydrocarbyl, halocarbyl, substitutedhalocarbyl, silylcarbyl, substituted silylcarbyl, germylcarbyl,substituted germylcarbyl substituent or a —NR′₂, —SR′, —OR′, —OSiR′₃, or—PR′₂ radical, wherein R′ is one of a halogen atom, a C₁-C₁₀ alkylgroup, or a C₆-C₁₀ aryl group.

According to some embodiments of the invention, at least one of R², R³,R⁴, R⁵, R⁶, R⁷, R⁸, R⁹, R¹⁰, R¹¹, R¹², and R¹³ is a cyclopropylsubstituent represented by the formula:

wherein each R′ in the cyclopropyls substituent is, independently,hydrogen, a substituted hydrocarbyl group, an unsubstituted hydrocarbylgroup, or a halogen.

According to some embodiments of the invention, the M is selected fromtitanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium,molybdenum and tungsten; each X is independently selected from hydrogen,halogen, hydroxy, substituted or unsubstituted C₁ to C₁₀ alkyl groups,substituted or unsubstituted C₁ to C₁₀ alkoxy groups, substituted orunsubstituted C₆ to C₁₄ aryl groups, substituted or unsubstituted C₆ toC₁₄ aryloxy groups, substituted or unsubstituted C₂ to C₁₀ alkenylgroups, substituted or unsubstituted C₇ to C₄₀ arylalkyl groups,substituted or unsubstituted C₇ to C₄₀ alkylaryl groups and substitutedor unsubstituted C₇ to C₄₀ arylalkenyl groups; or, optionally, arejoined together to form a C₄ to C₄₀ alkanediyl group or a conjugated C₄to C₄₀ diene ligand which is coordinated to M in a metallacyclopentenefashion; or optionally represent a conjugated diene, optionally,substituted with one or more groups independently selected fromhydrocarbyl, trihydrocarbylsilyl, and trihydrocarbylsilylhydrocarbylgroups, said diene having a total of up to 40 atoms not countinghydrogen and forming a π complex with M; each R², R⁴, R⁸ and R¹⁰ isindependently selected from hydrogen, halogen, substituted orunsubstituted C₁ to C₁₀ alkyl groups, substituted or unsubstituted C₆ toC₁₄ aryl groups, substituted or unsubstituted C₂ to C₁₀ alkenyl groups,substituted or unsubstituted C₇ to C₄₀ arylalkyl groups, substituted orunsubstituted C₇ to C₄₀ alkylaryl groups, substituted or unsubstitutedC₈ to C₄₀ arylalkenyl groups, and —NR′₂, —SR′, —OR′, —SiR′₃, —OSiR′₃,and —PR′₂ radicals wherein each R′ is independently selected fromhalogen, substituted or unsubstituted C₁ to C₁₀ alkyl groups andsubstituted or unsubstituted C₆ to C₁₄ aryl groups; R³, R⁵, R⁶, R⁷, R⁹,R¹¹, R¹², and R¹³ are each selected from the group consisting ofhydrogen, halogen, hydroxy, substituted or unsubstituted C₁ to C₁₀ alkylgroups, substituted or unsubstituted C₁ to C₁₀ alkoxy groups,substituted or unsubstituted C₆ to C₁₄ aryl groups, substituted orunsubstituted C₆ to C₁₄ aryloxy groups, substituted or unsubstituted C₂to C₁₀ alkenyl groups, substituted or unsubstituted C₇ to C₄₀ arylalkylgroups, substituted or unsubstituted C₇ to C₄₀ alkylaryl groups and C₇to C₄₀ substituted or unsubstituted arylalkenyl groups; and T isselected from:

—B(R¹⁴)—, —Al(R¹⁴)—, —Ge—, —Sn—, —O—, —S—, —SO—, —SO₂—, —N(R¹⁴)—, —CO—,—P(R¹⁴)—, and —P(O)(R¹⁴)—; wherein R¹⁴, R¹⁵, and R¹⁶ are eachindependently selected from hydrogen, halogen, C₁ to C₂₀ alkyl groups,C₆ to C₃₀ aryl groups, C₁ to C₂₀ alkoxy groups, C₂ to C₂₀ alkenylgroups, C₇ to C₄₀ arylalkyl groups, C₈ to C₄₀ arylalkenyl groups and C₇to C₄₀ alkylaryl groups, optionally R¹⁴ and R¹⁵, together with theatom(s) connecting them, form a ring; and M³ is selected from carbon,silicon, germanium, and tin; or T is represented by the formula:

wherein R¹⁷, R¹⁸, R¹⁹, R²⁰, R²¹, R²², R²³, and R²⁴ are eachindependently selected from hydrogen, halogen, hydroxy, substituted orunsubstituted C₁ to C₁₀ alkyl groups, substituted or unsubstituted C₁ toC₁₀ alkoxy groups, substituted or unsubstituted C₆ to C₁₄ aryl groups,substituted or unsubstituted C₆ to C₁₄ aryloxy groups, substituted orunsubstituted C₂ to C₁₀ alkenyl groups, substituted or unsubstituted C₇to C₄₀ alkylaryl groups, substituted or unsubstituted C₇ to C₄₀alkylaryl groups and substituted or unsubstituted C₈ to C₄₀ arylalkenylgroups; optionally two or more adjacent radicals R¹⁷, R¹⁸, R¹⁹, R²⁰,R²¹, R²², R²³, and R²⁴, including R²⁰ and R²¹, together with the atomsconnecting them, form one or more rings; and M² represents one or morecarbon atoms, or a silicon, germanium, or tin atom.

In a preferred embodiment in any of the processes described herein onecatalyst compound is used, e.g., where first and second (and or third)catalyst systems are present, the catalyst compounds are not different.

In some embodiments, two or more different catalyst compounds arepresent in the catalyst systems used herein. In some embodiments, two ormore different catalyst systems are present in the reaction zone wherethe process(es) described herein occur. When two transition metalcompound based catalysts are used in one reactor as a mixed catalystsystem, the two transition metal compounds should be chosen such thatthe two are compatible. A simple screening method such as by ¹H or ¹³CNMR, known to those of ordinary skill in the art, can be used todetermine which transition metal compounds are compatible.

The two transition metal compounds (pre-catalysts) may be used in anyratio. Preferred molar ratios of (A) transition metal compound to (B)transition metal compound fall within the range of (A:B) 1:1000 to1000:1, alternatively 1:100 to 500:1, alternatively 1:10 to 200:1,alternatively 1:1 to 100:1, alternatively 1:1 to 75:1, and alternatively5:1 to 50:1. The particular ratio chosen will depend on the exactpre-catalysts chosen, the method of activation, and the end productdesired. In a particular embodiment, when using the two pre-catalysts,where both are activated with the same activator. Useful molepercentages, based upon the molecular weight of the pre-catalysts, are10 to 99.9 mol % A to 0.1 to 90 mol % B, alternatively 25 to 99 mol % Ato 0.5 to 50 mol % B, alternatively 50 to 99 mol % A to 1 to 25 mol % B,and alternatively 75 to 99 mol % A to 1 to 10 mol % B.

In any embodiment of the invention in any embodiment of any formuladescribed herein, M is Zr or Hf.

In any embodiment of the invention in any embodiment of any formuladescribed herein, each X is, independently, selected from the groupconsisting of hydrocarbyl radicals having from 1 to 20 carbon atoms,hydrides, amides, alkoxides, sulfides, phosphides, halides, dienes,amines, phosphines, ethers, and a combination thereof, (two X's may forma part of a fused ring or a ring system), preferably each X isindependently selected from halides and C₁ to C₅ alkyl groups,preferably each X is a methyl group.

In a preferred embodiment of the invention in any embodiment of anyformula described herein, each R³, R⁵, R⁶, R⁷, R⁹, R¹¹, R¹², or R¹³ is,independently, hydrogen or a substituted hydrocarbyl group orunsubstituted hydrocarbyl group, or a heteroatom, preferably hydrogen,methyl, ethyl, propyl, butyl, pentyl, hexyl, or an isomer thereof.

In a preferred embodiment of any formula described herein, each R³, R⁴,R⁵, R⁶, R⁷, R⁹, R¹⁰, R¹¹, R¹², or R¹³ is, independently selected fromhydrogen, methyl, ethyl, phenyl, benzyl, cyclobutyl, cyclopentyl,cyclohexyl, naphthyl, anthracenyl, carbazolyl, indolyl, pyrrolyl,cyclopenta[b]thiopheneyl, fluoro, chloro, bromo, iodo and isomers ofpropyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, methylphenyl,dimethylphenyl, ethylphenyl, diethylphenyl, propylphenyl,dipropylphenyl, butylphenyl, dibutylphenyl, methylbenzyl,methylpyrrolyl, dimethylpyrrolyl, methylindolyl, dimethylindolyl,methylcarbazolyl, dimethylcarbazolyl, methylcyclopenta[b]thiopheneyldimethylcyclopenta[b]thiopheneyl.

In a preferred embodiment of the invention in any embodiment of anyformula described herein, T is a bridging group and comprises Si, Ge, orC, preferably T is dialkyl silicon or dialkyl germanium, preferably T isdimethyl silicon.

In a preferred embodiment of the invention in any embodiment of anyformula described herein, T is a bridging group and is represented byR′₂C, R′₂Si, R′₂Ge, R′₂CCR′₂, R′₂CCR′₂CR′₂, R′₂CCR′₂CR′₂CR′₂, R′C═CR′,R′C═CR′CR′₂, R′₂CCR′═CR′CR′₂, R′C═CR′CR′═CR′, R′C═CR′CR′₂CR′₂,R′₂CSiR′₂, R′₂SiSiR′₂, R₂CSiR′₂CR′₂, R′₂SiCR′₂SiR′₂, R′C═CR′SiR′₂,R′₂CGeR′₂, R′₂GeGeR′₂, R′₂CGeR′₂CR′₂, R′₂GeCR′₂GeR′₂, R′₂SiGeR′₂,R′C═CR′GeR′₂, R′B, R′₂C—BR′, R′₂C—BR′—CR′₂, R′₂C—O—CR′₂,R′₂CR′₂C—O—CR′₂CR′₂, R′₂C—O—CR′₂CR′₂, R′₂C—O—CR′═CR′, R′₂C—S—CR′₂,R′₂CR′₂C—S—CR′₂CR′₂, R′₂C—S—CR′₂CR′₂, R′₂C—S—CR′═CR′, R′₂C—Se—CR′₂,R′₂CR′₂C—Se—CR′₂CR′₂, R′₂C—Se—CR₂CR′₂, R′₂C—Se—CR′═CR′, R′₂C—N═CR′,R′₂C—NR′—CR′₂, R′₂C—NR′—CR′₂CR′₂, R′₂C—NR′—CR′═CR′,R′₂CR′₂C—NR′—CR′₂CR′₂, R′₂C—P═CR′, or R′₂C—PR′—CR′₂, where each R′ is,independently, hydrogen or a C₁ to C₂₀ containing hydrocarbyl,substituted hydrocarbyl, halocarbyl, substituted halocarbyl, silylcarbylor germylcarbyl substituent and optionally two or more adjacent R′ mayjoin to form a substituted or unsubstituted, saturated, partiallyunsaturated or aromatic, cyclic or polycyclic substituent. Preferably, Tis CH₂, CH₂CH₂, C(CH₃)₂, SiMe₂, SiPh₂, SiMePh, silylcyclobutyl(Si(CH₂)₃), (Ph)₂C, (p-(Et)₃SiPh)₂C, cyclopentasilylene (Si(CH₂)₄), orSi(CH₂)₅.

In embodiments of the invention, in any formula described herein, eachR² and R⁸, is independently, a C₁ to C₂₀ hydrocarbyl, or a C₁ to C₂₀substituted hydrocarbyl, C₁ to C₂₀ halocarbyl, C₁ to C₂₀ substitutedhalocarbyl, C₁ to C₂₀ silylcarbyl, C₁ to C₂₀ substituted silylcarbyl, C₁to C₂₀ germylcarbyl, or C₁ to C₂₀ substituted germylcarbyl substituents.Preferably, each R² and R⁸, is independently, methyl, ethyl, propyl,butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl oran isomer thereof, preferably cyclopropyl, cyclohexyl, (1-cyclohexylmethyl) methyl, isopropyl, and the like.

In embodiments of the invention, in any embodiment of any formuladescribed herein, R⁴ and R¹⁰ are, independently, a substituted orunsubstituted aryl group. Preferred substituted aryl groups include arylgroups where a hydrogen has been replaced by a hydrocarbyl, or asubstituted hydrocarbyl, halocarbyl, substituted halocarbyl,silylcarbyl, substituted silylcarbyl, germylcarbyl, or substitutedgermylcarbyl substituents, a heteroatom or heteroatom containing group.

In a preferred embodiment of the invention in any embodiment of anyformula described herein, R² and R⁸ are a C₁ to C₂₀ hydrocarbyl, such asmethyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl,decyl, undecyl, dodecyl or an isomer thereof, preferably cyclopropyl,cyclohexyl, (1-cyclohexyl methyl) methyl, or isopropyl; and R⁴ and R¹⁰are independently selected from phenyl, naphthyl, anthracenyl,2-methylphenyl, 3-methylphenyl, 4-methylphenyl, 2,3-dimethylphenyl,2,4-dimethylphenyl, 2,5-dimethylphenyl, 2,6-dimethylphenyl,3,4-dimethylphenyl, 3,5-dimethylphenyl, 2,4,5-trimethylphenyl,2,3,4,5,6-pentamethylphenyl, 2-ethylphenyl, 3-ethylphenyl,4-ethylphenyl, 2,3-diethylphenyl, 2,4-diethylphenyl, 2,5-diethylphenyl,2,6-diethylphenyl, 3,4-diethylphenyl, 3,5-diethylphenyl,3-isopropylphenyl, 4-isopropylphenyl, 3,5-di-isopropylphenyl,2,5-di-isopropylphenyl, 2-tert-butylphenyl, 3-tert-butylphenyl,4-tert-butylphenyl, 3,5-di-tert-butylphenyl, 2,5-di-tert-butylphenyl,cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, carbazolyl, indolyl,pyrrolyl, or cyclopenta[b]thiopheneyl. In a preferred embodiment, R²,R⁸, R⁴, and R¹⁰ are as described in the preceding sentence and R³, R⁵,R⁶, R⁷, R⁹, R¹¹, R¹², and R¹³ are hydrogen.

In embodiments according to the present invention, suitable MCNcompounds are represented by the formula (1):A_(e)MX_(n-e);or the formula (1c):TA₂MX_(n-2);wherein: e is 1 or 2; T is a bridging group between two A groups; each Ais a substituted monocyclic or polycyclic ligand that is pi-bonded to Mand optionally includes one or more ring heteroatoms selected fromboron, a group 14 atom that is not carbon, a group 15 atom, or a group16 atom, and when e is 2 each A may be the same or different, providedthat at least one A is substituted with at least one cyclopropylsubstituent directly bonded to any sp² carbon atom at a bondable ringposition of the ligand,wherein the cyclopropyl substituent is represented by the formula:

where each R′ is, independently, hydrogen, a substituted orunsubstituted hydrocarbyl group, or a halogen; M is a transition metalatom having a coordination number of n and selected from group 3, 4, or5 of the Periodic Table of Elements, or a lanthanide metal atom, oractinide metal atom; n is 3, 4, or 5; and each X is a univalent anionicligand, or two X's are joined and bound to the metal atom to form ametallocycle ring, or two X's are joined to form a chelating ligand, adiene ligand, or an alkylidene ligand.

In embodiments according to the present invention, the MCN compound maybe represented by the formula:T_(y)(A)_(e)(E)MX_(n-e-1)where E is J-R″_(x-1-y), J is a heteroatom with a coordination number ofthree from group 15 or with a coordination number of two from group 16of the Periodic Table of Elements; R″ is a C₁-C₁₀₀ substituted orunsubstituted hydrocarbyl radical; x is the coordination number of theheteroatom J where “x-1-y” indicates the number of R″ substituentsbonded to J; T is a bridging group between A and E, A and E are bound toM, y is 0 or 1; and A, e, M, X and n are as defined above.

In embodiments according to the present invention, the MCN compound maybe represented by one of the following formulae:

where M, T, X, are as defined in claim 1; J, R″, and n are as definedabove, and each R¹, R², R³, R⁴, R⁵, R⁶, R⁷, R⁸, R⁹, R¹⁰, R¹¹, R¹², R¹³,or R¹⁴ is, independently, hydrogen, a substituted hydrocarbyl group, anunsubstituted hydrocarbyl group, or a halide, provided that in formula1a and 1b, at least one of R¹, R², R³, R⁴, R⁵, R⁶, R⁷, R⁸, R⁹, R¹⁰, R¹¹,R¹², R¹³, or R¹⁴ is a cyclopropyl substituent and in formula 2a and 2bat least one of R¹, R², R³, R⁴, R⁵, R⁶, or R⁷, is a cyclopropylsubstituent; and provided that any adjacent R¹ to R¹⁴ groups that arenot a cyclopropyl substituent may form a fused ring or multicenter fusedring system where the rings may be aromatic, partially saturated orsaturated.

In embodiments according to the present invention, at least one A ismonocyclic ligand selected from the group consisting of substituted orunsubstituted cyclopentadienyl, heterocyclopentadienyl, and heterophenylligands provided that when e is one, the monocyclic ligand issubstituted with at least one cyclopropyl substituent, at least one A isa polycyclic ligand selected from the group consisting of substituted orunsubstituted indenyl, fluorenyl, cyclopenta[a]naphthyl,cyclopenta[b]naphthyl, heteropentalenyl, heterocyclopentapentalenyl,heteroindenyl, heterofluorenyl, heterocyclopentanaphthyl,heterocyclopentaindenyl, and heterobenzocyclopentaindenyl ligands.

MCN compounds suitable for use herein may further include one or moreof: dimethylsilylene-bis(2-cyclopropyl-4-phenylindenyl)zirconiumdichloride; dimethylsilylene-bis(2-cyclopropyl-4-phenylindenyl)hafniumdichloride; dimethylsilylene-bis(2-methyl-4-phenylindenyl)zirconiumdichloride; dimethylsilylene-bis(2-methyl-4-phenylindenyl)hafniumdichloride; dimethylsilylene-bis(2-methyl-4-orthobiphenylindenyl)hafniumdichloride;dimethylsilylene-bis(2-methyl-4-orthobiphenylindenyl)zirconiumdichloride;dimethylsilylene-(2-cyclopropyl-4-orthobiphenylindenyl)(2-methyl-4-3′,5′-di-t-butylphenylindenyl)hafniumdichloride;dimethylsilylene-(2-cyclopropyl-4-orthobiphenylindenyl)(2-methyl-4-3′,5′-di-t-butylphenylindenyl)zirconiumdichloride;dimethylsilylene-(2-isopropyl-4(4-t-butyl)phenyl)indenyl)(2-methyl-4-phenylindenyl)zirconiumdichloride;dimethylsilylene-(2-isopropyl-4(4-t-butyl)phenyl)indenyl)(2-methyl-4-phenylindenyl)hafniumdichloride;dimethylsilylene-(2-isopropyl-4(4-t-butyl)phenyl)indenyl)(2-methyl,4-t-butylindenyl)zirconium dichloride;dimethylsilylene-(2-isopropyl-4(4-t-butyl)phenyl)indenyl)(2-methyl,4-t-butylindenyl)hafnium dichloride;dimethylsilylene-(2-isopropyl-4(4-t-butyl)phenyl)indenyl)(2-methyl-4-phenylindacenyl)zirconiumdichloride;dimethylsilylene-(2-isopropyl-4(4-t-butyl)phenyl)indenyl)(2-methyl-4-phenylindacenyl)hafniumdichloride; dimethylsilylene(4-o-Biphenyl-2-(1-methylcyclohexyl)methyl-indenyl)(4-(3,5-di-tert-butylphenyl)-2-methyl-indenyl)zirconiumdichloride; and dimethylsilylene(4-o-Biphenyl-2-(1-methylcyclohexyl)methyl-indenyl)(4-(3,5-di-tert-butylphenyl)-2-methyl-indenyl)hafnium dichloride; where, in alternate embodiments, the dichloride inany of the compounds listed above may be replaced with dialkyl (such asdimethyl), dialkaryl, diflouride, diiodide, or dibromide, or acombination thereof.

In a preferred embodiment of the invention, the molar ratio of rac tomeso in the catalyst precursor compound is from 1:1 to 100:1, preferably5:1 to 90:1, preferably 7:1 to 80:1, preferably 5:1 or greater, or 7:1or greater, or 20:1 or greater, or 30:1 or greater, or 50:1 or greater.In an embodiment of the invention, the MCN catalyst comprises greaterthan 55 mol % of the racemic isomer, or greater than 60 mol % of theracemic isomer, or greater than 65 mol % of the racemic isomer, orgreater than 70 mol % of the racemic isomer, or greater than 75 mol % ofthe racemic isomer, or greater than 80 mol % of the racemic isomer, orgreater than 85 mol % of the racemic isomer, or greater than 90 mol % ofthe racemic isomer, or greater than 92 mol % of the racemic isomer, orgreater than 95 mol % of the racemic isomer, or greater than 98 mol % ofthe racemic isomer, based on the total amount of the racemic and mesoisomer-if any, formed. In a particular embodiment of the invention, thebridged bis(indenyl)metallocene transition metal compound formedconsists essentially of the racemic isomer.

Amounts of rac and meso isomers are determined by proton NMR. ¹H NMRdata are collected at 23° C. in a 5 mm probe using a 400 MHz Brukerspectrometer with deuterated methylene chloride. (Note that some of theexamples herein use deuterated benzene, but for purposes of the claims,methylene chloride shall be used.) Data is recorded using a maximumpulse width of 45°, 5 seconds between pulses and signal averaging 16transients. The spectrum is normalized to protonated methylene chloridein the deuterated methylene chloride, which is expected to show a peakat 5.32 ppm.

In some embodiments, two or more different MCN catalyst precursorcompounds are present in the catalyst system used herein. In someembodiments, two or more different MCN catalyst precursor compounds arepresent in the reaction zone where the process(es) described hereinoccur. When two transition metal compound based catalysts are used inone reactor as a mixed catalyst system, the two transition metalcompounds should be chosen such that the two are compatible. A simplescreening method such as by ¹H or ¹³C NMR, known to those of ordinaryskill in the art, can be used to determine which transition metalcompounds are compatible. It is preferable to use the same activator forthe transition metal compounds, however, two different activators, suchas two non-coordination anions, a non-coordinating anion activator andan alumoxane, or two different alumoxanes can be used in combination. Ifone or more transition metal compounds contain an X ligand which is nota hydride, hydrocarbyl, or substituted hydrocarbyl, then the alumoxane(or other alkylating agent) is typically contacted with the transitionmetal compounds prior to addition of the non-coordinating anionactivator.

The two transition metal compounds (pre-catalysts) may be used in anyratio. Preferred molar ratios of (A) transition metal compound to (B)transition metal compound fall within the range of (A:B) 1:1000 to1000:1, alternatively 1:100 to 500:1, alternatively 1:10 to 200:1,alternatively 1:1 to 100:1, alternatively 1:1 to 75:1, and alternatively5:1 to 50:1. The particular ratio chosen will depend on the exactpre-catalysts chosen, the method of activation, and the end productdesired. In a particular embodiment, when using the two pre-catalysts,where both are activated with the same activator, useful molepercentages, based upon the molecular weight of the pre-catalysts, are10 to 99.9 mol % A to 0.1 to 90 mol % B, alternatively 25 to 99 mol % Ato 0.5 to 50 mol % B, alternatively 50 to 99 mol % A to 1 to 25 mol % B,and alternatively 75 to 99 mol % A to 1 to 10 mol % B.

Chain Transfer Agents: This invention further relates to methods topolymerize olefins using the above complex in the presence of a chaintransfer agent (“CTA”). The CTA can be any desirable chemical compoundsuch as those disclosed in WO 2007/130306. Preferably, the CTA isselected from Group 2, 12 or 13 alkyl or aryl compounds; preferablyzinc, magnesium or aluminum alkyls or aryls; preferably where the alkylis a C₁ to C₃₀ alkyl, alternately a C₂ to C₂₀ alkyl, alternately a C₃ toC₁₂ alkyl, typically selected independently from methyl, ethyl, propyl,butyl, isobutyl, tertbutyl, pentyl, hexyl, cyclohexyl, phenyl, octyl,nonyl, decyl, undecyl, and dodecyl; e.g., dialkyl zinc compounds, wherethe alkyl is selected independently from methyl, ethyl, propyl, butyl,isobutyl, tertbutyl, pentyl, hexyl, cyclohexyl, and phenyl, wheredi-ethylzinc is particularly preferred; or e.g., trialkyl aluminumcompounds, where the alkyl is selected independently from methyl, ethyl,propyl, butyl, isobutyl, tertbutyl, pentyl, hexyl, cyclohexyl, andphenyl; or e.g., diethyl aluminum chloride, diisobutylaluminum hydride,diethylaluminum hydride, di-n-octylaluminum hydride, dibutylmagnesium,diethylmagnesium, dihexylmagnesium, and triethylboron.

Useful CTAs are typically present at from 10, or 20, or 50, or 100,equivalents to 600, or 700, or 800, or 1000, equivalents relative to thecatalyst component. Alternately the CTA is preset at a catalystcomplex-to-CTA molar ratio of from about 1:3000 to 10:1; alternatively1:2000 to 10:1; alternatively 1:1000 to 10:1; alternatively, 1:500 to1:1; alternatively 1:300 to 1:1; alternatively 1:200 to 1:1;alternatively 1:100 to 1:1; alternatively 1:50 to 1:1; or/andalternatively 1:10 to 1:1.

Monomers: Monomers useful herein include substituted or unsubstituted C₂to C₄₀ alpha olefins, preferably C₂ to C₂₀ alpha olefins, preferably C₂to C₁₂ alpha olefins, preferably ethylene, propylene, butene, pentene,hexene, heptene, octene, nonene, decene, undecene, dodecene and isomersthereof. In a preferred embodiment, the monomer comprises propylene andoptional co-monomer(s) comprising one or more of ethylene or C₄ to C₄₀olefins, preferably C₄ to C₂₀ olefins, or preferably C₆ to C₁₂ olefins.The C₄ to C₄₀ olefin monomers may be linear, branched, or cyclic. The C₄to C₄₀ cyclic olefins may be strained or unstrained, monocyclic orpolycyclic, and may optionally include heteroatoms and/or one or morefunctional groups. In a preferred embodiment of the invention, themonomer is propylene and no co-monomer is present.

Exemplary C₂ to C₄₀ olefin monomers and optional co-monomers includeethylene, propylene, butene, pentene, hexene, heptene, octene, nonene,decene, undecene, dodecene, norbornene, norbornadiene,dicyclopentadiene, cyclopentene, cycloheptene, cyclooctene,cyclooctadiene, cyclododecene, 7-oxanorbornene, 7-oxanorbornadiene,substituted derivatives thereof, and isomers thereof, preferably hexene,heptene, octene, nonene, decene, dodecene, cyclooctene,1,5-cyclooctadiene, 1-hydroxy-4-cyclooctene, 1-acetoxy-4-cyclooctene,5-methylcyclopentene, cyclopentene, dicyclopentadiene, norbornene,norbornadiene, and their respective homologs and derivatives, preferablynorbornene, norbornadiene, and dicyclopentadiene.

In a preferred embodiment, one or more dienes are present in the polymerproduced herein at up to 10 weight %, preferably at 0.00001 to 1.0weight %, preferably 0.002 to 0.5 weight %, even more preferably 0.003to 0.2 weight %, based upon the total weight of the composition. In someembodiments 500 ppm or less of diene is added to the polymerization,preferably 400 ppm or less, preferably or 300 ppm or less. In otherembodiments, at least 50 ppm of diene is added to the polymerization, or100 ppm or more, or 150 ppm or more.

Preferred diolefin monomers useful in this invention include anyhydrocarbon structure, preferably C₄ to C₃₀, having at least twounsaturated bonds, wherein at least two of the unsaturated bonds arereadily incorporated into a polymer by either a stereospecific or anon-stereospecific catalyst(s). It is further preferred that thediolefin monomers be selected from alpha, omega-diene monomers (i.e.,di-vinyl monomers). More preferably, the diolefin monomers are lineardi-vinyl monomers, most preferably those containing from 4 to 30 carbonatoms. Examples of preferred dienes include butadiene, pentadiene,hexadiene, heptadiene, octadiene, nonadiene, decadiene, undecadiene,dodecadiene, tridecadiene, tetradecadiene, pentadecadiene,hexadecadiene, heptadecadiene, octadecadiene, nonadecadiene, icosadiene,heneicosadiene, docosadiene, tricosadiene, tetracosadiene,pentacosadiene, hexacosadiene, heptacosadiene, octacosadiene,nonacosadiene, triacontadiene, particularly preferred dienes include1,6-heptadiene, 1,7-octadiene, 1,8-nonadiene, 1,9-decadiene,1,10-undecadiene, 1,11-dodecadiene, 1,12-tridecadiene,1,13-tetradecadiene, and low molecular weight polybutadienes (Mw lessthan 1000 g/mol). Preferred cyclic dienes include cyclopentadiene,vinylnorbornene, norbornadiene, ethylidene norbornene, divinylbenzene,dicyclopentadiene or higher ring containing diolefins with or withoutsubstituents at various ring positions.

Preferably, the polymerization or copolymerization is carried out usingolefins such as ethylene, propylene, 1-butene, 1-hexene,4-methyl-1-pentene, and 1-octene, vinylcyclohexane, norbornene andnorbornadiene. In particular, propylene and ethylene are polymerized.

In some embodiments, where butene is the co-monomer, the butene sourcemay be a mixed butene stream comprising various isomers of butene. The1-butene monomers are expected to be preferentially consumed by thepolymerization process. Use of such mixed butene streams will provide aneconomic benefit, as these mixed streams are often waste streams fromrefining processes, for example, C₄ raffinate streams, and can thereforebe substantially less expensive than pure 1-butene.

In preferred embodiments, the monomers comprise 0 wt % diene monomer inany stage, preferably in all stages.

Preferably, the co-monomer(s) are present in the final propylene polymercomposition at less than 50 mol %, preferably from 0.5 to 45 mol %,preferably from 1 to 30 mol %, preferably from 3 to 25 mol %, preferablyfrom 5 to 20 mol %, preferably from 7 to 15 mol %, with the balance ofthe copolymer being made up of the main monomer (e.g., propylene), basedon the molecular.

In a preferred embodiment of the invention, the polymer produced instage A (and/or stages A1 and A2, e.g., when polymer A is bimodal) isiPP, preferably isotactic homopolypropylene and the polymer produced instage B comprises propylene and from 0.5 to 50 mol % (preferably from0.5 to 45 mol %, preferably from 1 to 30 mol %, preferably from 3 to 25mol %, preferably from 5 to 20 mol %, preferably from 7 to 15 mol %,with the balance of the copolymer being made up of propylene) ofethylene or C₄ to C₂₀ alpha olefin, preferably ethylene and butene,hexene, and/or octene.

In a preferred embodiment, stage A may comprise a plurality ofsubstages, e.g., stage A1, stage A2, etc. As used herein stage A refersto all of the substages. In a preferred embodiment of the invention, thepolymer produced in stage A1 is iPP, preferably isotactichomopolypropylene, and the polymer produced in stage A2 is an iPP.

In a preferred embodiment of the invention, the polymer produced instage A1 is iPP, preferably isotactic homopolypropylene, and the polymerproduced in stage A2 is an iPP, and the polymer produced in stage Bcomprises propylene and from 0.5 to 50 mol % (preferably from 0.5 to 45mol %, preferably from 1 to 30 mol %, preferably from 3 to 25 mol %,preferably from 5 to 20 mol %, preferably from 7 to 15 mol %, with thebalance of the copolymer being made up of propylene) of ethylene andbutene, or ethylene and hexene, or ethylene and octene.

Sequential Polymerization: The propylene polymer compositions accordingto embodiments of the invention may be prepared using polymerizationprocesses such as a two-stage process in two reactors or a three-stageprocess in three reactors, although it is also possible to produce thesecompositions in a single reactor. In embodiments, each stage may beindependently carried out in either the gas, solution or liquid slurryphase. For example, the first stage may be conducted in the gas phaseand the second in liquid slurry or vice versa and the optional thirdstage in gas or slurry phase. Alternatively, each phase may be the samein the various stages. The propylene polymer compositions of thisinvention can be produced in multiple reactors, preferably two or three,operated in series, where component A (including components A1 and A2 ifpresent) is preferably polymerized first in a gas phase, liquid slurryor solution polymerization process. Component B (the polymeric materialproduced in the presence of component A) is preferably polymerized in asecond reactor such as a gas phase or slurry phase reactor. In analternative embodiment, component A can be made in at least tworeactors, stages A1 and A2, in order to obtain fractions with differentproperties, e.g., varying molecular weights, polydispersities, melt flowrates, or the like.

As used herein “stage” is defined as that portion of a polymerizationprocess during which one component of the in-reactor composition,component A (including components A1 and A2 if present) or component B(or component C, if another stage is present), is produced. One ormultiple reactors may be used during each stage. The same or differentpolymerization process may be used in each stage. For purposes ofexample, clarity and convenience, component A and/or Stage A may bereferred to herein below as iPP and the stage producing thepolypropylene, component A1 and/or Stage A1 may be referred to hereinbelow as the first iPP mode and the stage producing the firstpolypropylene mode, component A2 and/or Stage A2 may be referred toherein below as the second iPP mode and the stage producing the secondpolypropylene mode, and component B and/or Stage B may be referred toherein below as the rubber and the stage producing the rubber, it beingunderstood that the polymers may be produced in any order or in the samereactor and/or series of reactors.

The stages of the processes of this invention can be carried out in anymanner known in the art, in solution, in suspension or in the gas phase,continuously or batch wise, or any combination thereof, in one or moresteps. Homogeneous polymerization processes are useful. For purposesherein, a homogeneous polymerization process is defined to be a processwhere at least 90 wt % of the product is soluble in the reaction media.A bulk homogeneous process is also useful, wherein for purposes herein abulk process is defined to be a process where monomer concentration inall feeds to the reactor is 70 volume % or more. Alternately, inembodiments, no solvent or diluent may be present or added in thereaction medium, except for the small amounts used as the carrier forthe catalyst system or other additives, or amounts typically found withthe monomer; e.g., propane in propylene as is known in the art. The term“gas phase polymerization” refers to the state of the monomers duringpolymerization, where the “gas phase” refers to the vapor state of themonomers. In another embodiment, a slurry process is used in one or morestages. As used herein the term “slurry polymerization process” means apolymerization process where a supported catalyst is employed andmonomers are polymerized on the supported catalyst particles, and atleast 95 wt % of polymer products derived from the supported catalystare in granular form as solid particles (not dissolved in the diluent).Gas phase polymerization processes are particularly preferred and can beused in one or more stages.

In embodiments of the invention, stage A1 produces hPP, and stage Bproduces propylene copolymer, such as propylene-ethylene copolymer. Inan alternate embodiment of the invention, stage A produces hPP and stageB produces hPP. In an alternate embodiment of the invention, stage A1and stage A2 produce hPP and stage B produces propylene copolymer, suchas propylene-ethylene copolymer. In alternate embodiments of theinvention, stage B produces hPP, and stage A produces propylenecopolymer, such as propylene-ethylene copolymer. In an alternateembodiment of the invention, stage A1 and stage A2 produce hPP.

In embodiments of the invention, if the polymerization is carried out asa suspension (slurry) or solution polymerization, an inert solvent ordiluent may be used, for example, the polymerization may be carried outin suitable diluents/solvents. Suitable diluents/solvents forpolymerization include non-coordinating, inert liquids. Examples includestraight and branched-chain hydrocarbons, such as isobutane, butane,pentane, isopentane, hexanes, isohexane, heptane, octane, dodecane, andmixtures thereof; cyclic and alicyclic hydrocarbons, such ascyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, andmixtures thereof, such as can be found commercially (ISOPAR™);perhalogenated hydrocarbons, such as perfluorinated C₄₋₁₀ alkanes,chlorobenzene, and aromatic and alkylsubstituted aromatic compounds,such as benzene, toluene, mesitylene, and xylene. Suitablediluents/solvents also include liquid olefins which may act as monomersor co-monomers including ethylene, propylene, 1-butene, 1-hexene,1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-octene, 1-decene,and mixtures thereof. In a preferred embodiment, aliphatic hydrocarbonsolvents are used as the solvent, such as isobutane, butane, pentane,isopentane, hexanes, isohexane, heptane, octane, dodecane, and mixturesthereof; cyclic and alicyclic hydrocarbons, such as cyclohexane,cycloheptane, methylcyclohexane, methylcycloheptane, and mixturesthereof. In another embodiment, the diluent/solvent is not aromatic,preferably aromatics are present in the diluent/solvent at less than 1wt %, preferably less than 0.5 wt %, preferably less than 0 wt % basedupon the weight of the diluents/solvents. It is also possible to usemineral spirit or a hydrogenated diesel oil fraction as a solvent.Toluene may also be used. The polymerization is preferably carried outin the liquid monomer(s). If inert solvents are used, the monomer(s) is(are) typically metered in gas or liquid form.

In embodiments of the invention, the feed concentration of the monomersand co-monomers for the polymerization is 60 vol % solvent or less, or40 vol % or less, or 20 vol % or less, based on the total volume of thefeedstream. In embodiments, the polymerization is run in a bulk process.

In embodiments of the invention, polymerizations can be run at anytemperature and/or pressure suitable to obtain the desired polymers.Typical temperatures and/or pressures in any stage include a temperaturegreater than 30° C., or greater than 50° C., or greater than 65° C., orgreater than 70° C., or greater than 75° C., alternately less than 300°C., or less than 200° C., or less than 150° C., or less than 140° C.;and/or at a pressure in the range of from 100 kPa to 20 MPa, about 0.35MPa to about 10 MPa, or from about 0.45 MPa to about 6 MPa, or fromabout 0.5 MPa to about 5 MPa.

In embodiments, polymerization in any stage may include a reaction runtime up to 300 minutes, or in the range of from about 5 to 250 minutes,or from about 10 to 120 minutes. In embodiments of the invention, in acontinuous process the polymerization time for all stages is from 1 to600 minutes, or 5 to 300 minutes, or from about 10 to 120 minutes.

Hydrogen and/or other CTA's may be added to one, two, or more reactorsor reaction zones. In embodiments, hydrogen and/or CTA are added tocontrol Mw and MFR of the polymer produced. In embodiments, the overallpressure in the polymerization in each stage is at least about 0.5 bar,or at least about 2 bar, or at least about 5 bar. In embodiments,pressures higher than about 100 bar, e.g., higher than about 80 bar and,in particular, higher than about 64 bar may not be utilized. In someembodiments, hydrogen is present in the polymerization reaction zone ata partial pressure of from 0.001 to 100 psig (0.007 to 690 kPa), or from0.001 to 50 psig (0.007 to 345 kPa), or from 0.01 to 25 psig (0.07 to172 kPa), or 0.1 to 10 psig (0.7 to 70 kPa). In embodiments of theinvention, hydrogen, and/or CTA, may be added to the first reactor, asecond, or third, or subsequent reactor, or any combination thereof.Likewise, in a three stage process hydrogen may be added to the firststage, and/or the second stage, and/or the third stage. In embodimentsof the invention, hydrogen is added in a higher concentration to thesecond stage as compared to the first stage. In an alternate embodimentof the invention, hydrogen is added in a higher concentration to thefirst stage as compared to the second stage. For further information onstage hydrogen addition in impact copolymer production please see U.S.Ser. No. 61/896,291, filed Oct. 28, 2013, published as US 2015-0119537,incorporated herein by reference.

Polymerization processes of this invention can be carried out in each ofthe stages in a batch, semi-batch, or continuous mode. If two or morereactors (or reaction zones) are used, preferably they are combined soas to form a continuous process. In embodiments of the invention,polymerizations can be run at any temperature and/or pressure suitableto obtain the desired polymers. In embodiments of the invention, theprocess to produce the propylene polymer composition is continuous.

In embodiments of the invention, in the first stage, A, propylene andfrom about 0 wt % to 15 wt % C₂ and/or C₄ to C₂₀ alpha olefins(alternately 0.5 to 10 wt %, alternately 1 to 5 wt %), based upon theweight of the monomer/co-monomer feeds (and optional H₂), are contactedwith the supported MCN catalyst(s) described herein under polymerizationconditions to form Component A. In the first stage, the monomerspreferably comprise propylene and optional co-monomers comprising one ormore of ethylene and/or C₄ to C₂₀ olefins, preferably C₄ to C₁₆ olefins,or preferably C₆ to C₁₂ olefins. The C₄ to C₂₀ olefin monomers may belinear, branched, or cyclic. The C₄ to C₂₀ cyclic olefins may bestrained or unstrained, monocyclic or polycyclic, and may optionallyinclude heteroatoms and/or one or more functional groups. In a preferredembodiment of the invention, the monomer in stage A (or stages A1 andA2) is propylene and no co-monomer is present.

In embodiments of the invention, in the second stage, B, propylene andfrom about 0 wt % to 15 wt % C₂ and/or C₄ to C₂₀ alpha olefins(alternately 0.5 to 10 wt %, alternately 1 to 5 wt %), based upon theweight of the monomer/co-monomer feeds, are contacted with the MCNcatalyst(s) described herein under polymerization conditions to formComponent B. In the second stage, the monomers preferably comprisepropylene and optional co-monomers comprising one or more of ethyleneand/or C₄ to C₂₀ olefins, preferably C₄ to C₁₆ olefins, or preferably C₆to C₁₂ olefins. The C₄ to C₂₀ olefin monomers may be linear, branched,or cyclic. The C₄ to C₂₀ cyclic olefins may be strained or unstrained,monocyclic or polycyclic, and may optionally include heteroatoms and/orone or more functional groups. In a preferred embodiment of theinvention, the monomer in stage B is propylene and co-monomer ispresent.

Alternately, in the second stage, Component A, propylene and optionallyfrom about 1 wt % to 15 wt % (preferably 3 wt % to 10 wt %), based uponthe weight of the monomer/co-monomer feeds, of one or more co-monomers(such as ethylene or C₄ to C₂₀ alpha olefins) are contacted in thepresence of the MCN catalyst system(s) described herein and optionalhydrogen/CTA, under polymerization conditions to form Component Bintimately mixed with Component A which forms the propylene polymercomposition. In the second stage, the optional co-monomers may compriseone or more of ethylene and C₃ to C₂₀ olefins, preferably C₄ to C₁₆olefins, or preferably C₆ to C₁₂ olefins. The C₄ to C₂₀ olefin monomersmay be linear, branched, or cyclic. The C₄ to C₂₀ cyclic olefins may bestrained or unstrained, monocyclic or polycyclic, and may optionallyinclude heteroatoms and/or one or more functional groups.

Alternately, in the second stage, Component A and propylene arecontacted in the presence of the MCN catalyst system(s) described hereinand hydrogen/CTA, under polymerization conditions to form Component Bintimately mixed with Component A which forms the propylene polymercomposition.

Alternately, in the second stage, Component A and ethylene are contactedin the presence of the MCN catalyst system(s) described herein andhydrogen, under polymerization conditions to form Component B intimatelymixed with Component A which forms the propylene polymer composition.

The catalyst systems used in the stages may be the same or different andare preferably the same. In embodiments of the invention, the catalystsystem used in Stage A (stages A1 and A2) is transferred with thepolymerizate (e.g., Component A) to Stage B, where it is contacted withadditional monomer to form Component B, and thus the final propylenepolymer composition. In other embodiments of the invention, catalyst isprovided to one, two, or all three reaction zones.

In embodiments of the invention, Stage A (stages A1 and A2) produces ahomopolypropylene, and Stage B produces a copolymer of ethylene-butene,ethylene-hexene, ethylene-octene, ethylene-propylene,ethylene-propylene-butene, ethylene-propylene-hexene, orethylene-propylene-octene.

In an embodiment of the invention, little or no scavenger is used in thepolymerization in any stage to produce the polymer, i.e., scavenger(such as trialkyl aluminum) is present at a molar ratio of scavengermetal to transition metal of 0:1, alternately less than 100:1, or lessthan 50:1, or less than 15:1, or less than 10:1, or less than 1:1, orless than 0.1:1.

Other additives may also be used in the polymerization in any stage, asdesired, such as one or more scavengers, promoters, modifiers, hydrogen,CTAs other than or in addition to hydrogen (such as diethyl zinc),reducing agents, oxidizing agents, aluminum alkyls, or silanes, or thelike.

In an embodiment of the invention, the productivity of the catalystsystem in a single stage or in all stages combined is at least 50g(polymer)/g(cat)/hour, preferably 500 or more g(polymer)/g(cat)/hour,preferably 800 or more g(polymer)/g(cat)/hour, preferably 5000 or moreg(polymer)/g(cat)/hour, preferably 50,000 or moreg(polymer)/g(cat)/hour.

In an embodiment of the invention, the activity of the catalyst systemin a single stage or in all stages combined is at least 50 kg P/mol cat,preferably 500 or more kg P/mol cat, preferably 5000 or more kg P/molcat, preferably 50,000 or more kg P/mol cat. According to someembodiments of the invention, the catalyst system in a single stage orin all stages combined provides a catalyst activity of at least 800, orat least 1000, or at least 1500, or at least 2000 g propylene polymerproduced per g of the catalyst precursor compound per hour.

In another embodiment of the invention, the conversion of olefin monomeris at least 10%, based upon polymer yield and the weight of the monomerentering the reaction zone, or 20% or more, or 30% or more, or 50% ormore, or 80% or more. A “reaction zone”, also referred to as a“polymerization zone”, is a vessel or portion thereof or combination ofvessels, where the polymerization process takes place, for example, abatch reactor. When multiple reactors are used in either series orparallel configuration, each reactor is considered as a separatepolymerization zone. For a multi-stage polymerization in both a batchreactor and a continuous reactor, each polymerization stage isconsidered as a separate polymerization zone. In preferred embodiments,the polymerization occurs in two, three, four, or more reaction zones.In another embodiment of the invention, the conversion of olefin monomeris at least 10%, based upon polymer yield and the weight of the monomerentering all reaction zones, or 20% or more, or 30% or more, or 50% ormore, or 80% or more.

In embodiments of the invention, processes to produce polymercompositions, such as heterophasic copolymers and/or impact copolymers(ICPs) utilizing a single MCN catalyst may comprise first polymerizingethylene, and then using the same or a different catalyst, polymerizingpropylene in the presence of the polyethylene. Typically, propylene isfirst polymerized and then modified with ethylene, ethylene polymers byblending and/or by modifying with ethylene/propylene copolymers. Byreversing the order of polymerizations and by selecting an appropriatecatalyst, ICPs with ethylene content of greater than 30 wt % areachieved.

In embodiments of the invention, the processes may comprise contactingethylene and, optionally, a C₂ to a C₁₂ alpha-olefin comonomer underpolymerization conditions in a first stage in the presence of a firstMCN catalyst system to form Component A; contacting Component A of stepa) with a C₃ to a C₁₂ alpha-olefin monomer under polymerizationconditions in a second stage in the presence of a second MCN catalystsystem to form Component B, wherein the first MCN catalyst system ispresent in both steps a and b and/or additional MCN catalyst is added tothe reaction mixture between steps a and b and the first MCN catalystsystem may be the same as the second MCN catalyst system; and obtainingan ethylene-based in-reactor composition comprising Component A andComponent B, wherein the ethylene-based in-reactor composition has fromgreater than 20 mol % ethylene, based on the molecular weight of theethylene-based in-reactor composition. In embodiments of the invention,the ethylene-based in-reactor composition may have a multimodal meltingpoint. In embodiments of the invention, an ICP is provided that has anethylene content of greater than 20 mol %, or greater than 30 mol %, orgreater than about 40 mol %, or greater than about 50 mol %, or greaterthan about 65 mol %, or greater than 85 mol %, based on the molecularweight of the ICP.

In still another aspect, the reaction sequence of step 1 and step 2 canbe carried out immediately. Alternatively, there can be a period of timebetween generating the polyethylene and further reacting thepolyethylene with propylene of 1 second or more, alternately 30 secondsor more, alternately 1 minute or more, alternately 15 minutes or more,alternately 30 minutes or more, alternately 1 hour or more, alternately2 hours or more, alternately 1 day or more.

High Porosity Propylene Polymer Products: The polymer products hereinmay comprise polypropylene, such as, for example, iPP, highly isotacticpolypropylene, sPP, hPP, and RCP.

In any embodiment of the invention, the propylene polymer made in stageA1 is iPP or highly isotactic polypropylene, preferablyhomopolypropylene. In any embodiment of the invention, the propylenepolymer made in stage A2 is propylene copolymer, preferably a copolymerof propylene and a C₂ or C₄ to C₂₀ olefin, preferably ethylene). In anembodiment of the invention, the propylene polymer made in stage A1 isisotactic homopolypropylene or highly isotactic homopolypropylene. In anembodiment of the invention, the propylene polymer made in stage A2 isethylene-propylene rubber.

According to some embodiments of the invention, the propylene polymermatrix has a porosity of 15% or more, e.g., from 20%, or 25%, or 30%, or35%, or 40%; up to 85%, 80%, 75%, 70%, 60%, or 50%, based on the totalvolume of the propylene polymer matrix, determined by mercuryinfiltration porosimetry.

According to some embodiments of the invention, the propylene polymermatrix has a median PD less than 165 μm, e.g., between greater than 6and less than 160 μm, as determined by mercury intrusion porosimetry. Inadditional or alternate embodiments, the propylene polymer matrix has amedian PD greater than 0.1, greater than 1, or greater than 2, orgreater than 5, or greater than 6, or greater than 8, or greater than10, or greater than 12, or greater than 15, or greater than 20 μm; up toless than 50, or less than 60, or less than 70, or less than 80, or lessthan 90, or less than 100, or less than 120, or less than 125, or lessthan 140, or less than 150, or less than 160, or less than 165 μm.

According to some embodiments of the invention, the propylene polymerhas more than 5, or more than 10, or more than 15 regio defects per10,000 propylene units, determined by ¹³C NMR.

According to some embodiments of the invention, the propylene polymerhas a 1% Secant flexural modulus of at least 1000 MPa, e.g., at least1300 MPa, or at least 1500 MPa, or at least 1700 MPa, or at least 1800MPa, or at least 1900 MPa, or at least 2000 MPa, determined according toASTM D 790 (A, 1.0 mm/min).

According to some embodiments of the invention, the propylene polymerhas a multimodal MWD. According to some embodiments of the invention,the propylene polymer has a multimodal PSD.

According to some embodiments of the invention, the propylene polymerfurther comprises a second polymer at least partially filling the poresin the matrix. For example, the second polymer can be a rubber fillmaterial at least partially filling the pores, such as, for example, anethylene-propylene copolymer, e.g., a copolymer of ethylene and fromabout 3 wt % to 75 wt % of one or more C₃ to C₂₀ alpha olefins by weightof the ethylene copolymer. In some embodiments, the propylene polymer inwhich the pores are formed may conveniently be referred to herein as the“first polymer,” without implying that the second polymer is necessarilypresent or, if present, that the first polymer is formed before thesecond polymer.

In embodiments according to the invention, the propylene polymer isheterophasic and/or an impact copolymer, for example, comprising asecond polymer, e.g., fill rubber, disposed in the pores in an amount ofat least 20, or at least 30, or at least 40, or at least 50, or at least60, or at least 70, or at least 80, or up to 85 vol % or more, based ona total volume of the impact copolymer. In additional or alternateembodiments, the second polymer is disposed essentially entirely withinthe pores, i.e., an exterior surface of the polymer particle isessentially free of the second polymer so that the polymer particlesremain free flowing and do not agglomerate and plug processing equipmentsuch as reactors, lines, fittings, and/or valves used in theirproduction.

According to some embodiments of the invention, the propylene polymer isin a particulated form, such as, for example, wherein at least 95% byweight has a particle size greater than about 120 μm, e.g., from 150,200, 300, 400, or 500 μm up to 10, 5, or 1 mm.

According to some embodiments of the invention, the polymer is made witha single site catalyst system, e.g., it has properties or a combinationof properties generally attributed to and/or which can be obtained bypolymerization with a single site catalyst system as opposed to aZiegler-Natta (ZN) catalyst system, such as higher Mw, lower PDI, lowercold xylene extractables, more uniformly distributed stereoirregularities, higher composition distribution breadth index (CBDI) inthe case where a comonomer is present, between 5 and 200 regio defectsper 10,000 propylene units, and the like. In additional or alternateembodiments, the polymer further comprises an active single sitecatalyst system, a residue of a single site catalyst system, or acombination thereof, wherein the single site catalyst system comprises asingle site catalyst precursor compound, an activator for the precursorcompound, and a support.

According to some embodiments of the invention, the propylene polymerfurther comprises an active catalyst system comprising a single sitecatalyst precursor compound, an activator for the precursor compound,and a support distributed in a porous matrix of the propylene polymer.

According to some embodiments of the invention, the matrix of thepropylene polymer is comprised of a plurality of polymer subglobulesdefining interstitial spaces forming the pores in polymer globules. Inadditional or alternate embodiments, the matrix further comprisesdispersed microparticles of a catalyst system comprising a single sitecatalyst precursor compound, an activator, and a support. In additionalor alternate embodiments, the support comprises (1) silica agglomerateshaving an average PS of more than 30 μm up to 200 μm and comprising aplurality of primary particles having a relatively smaller average PSfrom 1 nm to 50 μm, wherein the silica agglomerates have a surface areaof 400 m²/g or more, a pore volume of from 0.5 to 2 mL/g, and a meanpore diameter of from 1 to 20 nm as determined by BET nitrogenadsorption; or (2) a plurality of free primary particles spaced apartfrom each other in the polymer subglobules, wherein the primaryparticles comprise one or more of the primary particles disagglomeratedfrom the silica agglomerates; or (3) a combination thereof.

Multimodal Propylene Polymer Products: In a preferred embodiment of theinvention, the propylene polymer compositions produced herein may have amultimodal MWD of polymer species as determined by GPC-DRI. Bymultimodal MWD is meant that the GPC-DRI trace has more than one peak orinflection point. In a preferred embodiment of the invention, thepropylene polymer compositions produced herein may have a bimodal MWD ofpolymer species as determined by GPC-DRI. In a preferred embodiment ofthe invention, the propylene polymer compositions produced herein mayhave a unimodal MWD of polymer species as determined by GPC-DRI.

In an additional or alternative preferred embodiment of the invention,the propylene polymer compositions produced herein may have a multimodalPSD as determined by laser diffraction. By multimodal PSD is meant thatthe PSD curve with respect to volume has more than one peak orinflection point. In a preferred embodiment of the invention, thepropylene polymer compositions produced herein may have a bimodal PSD asdetermined by laser diffraction. In another preferred embodiment of theinvention, the propylene polymer compositions produced herein may have aunimodal PSD as determined by laser diffraction.

In any embodiment of the invention, the propylene polymer (the A1component) advantageously has less than 200 regio defects (defined asthe sum of 2,1-erythro and 2,1-threo insertions, and 3,1-isomerizations)per 10,000 propylene units, alternatively more than 5, 10, or 15 andless than 200 regio defects per 10,000 propylene units, alternativelymore than 17 and less than 175 regio defects per 10,000 propylene units,alternatively more than 20 or 30 or 40, but less than 200 regio defects,alternatively less than 150 regio defects per 10,000 propylene units.The regio defects are determined using ¹³C NMR spectroscopy as describedbelow.

In any embodiment of the invention, the propylene polymer compositionproduced herein, particularly the composition produced after Stage A1and Stage A2 (the combined A1 & A2 components), has less than 200 regiodefects (defined as the sum of 2,1-erythro and 2,1-threo insertions, and3,1-isomerizations) per 10,000 propylene units, alternatively less than150 regio defects per 10,000 propylene units, alternatively more than 5and less than 200 regio defects per 10,000 propylene units,alternatively more than 15 and less than 175 regio defects per 10,000propylene units, alternatively more than 17 and less than 175 regiodefects per 10,000 propylene units.

In any embodiment of the invention, the propylene polymer (A1) componentcan have a melting point (Tm, DSC peak second melt) of at least 145° C.,or at least 150° C., or at least 152° C., or at least 155° C., or atleast 160° C., or at least 165° C., preferably from about 145° C. toabout 175° C., about 150° C. to about 170° C., or about 152° C. to about165° C.

In any embodiment of the invention, the propylene polymer compositionsproduced herein, particularly the composition produced after Stage A1and Stage A2 (the combined A1 & A2 components), can have a melting point(Tm, DSC peak second melt) of at least 145° C., or at least 150° C., orat least 152° C., or at least 155° C., or at least 160° C., or at least165° C., preferably from about 145° C. to about 175° C., about 150° C.to about 170° C., or about 152° C. to about 165° C.

In any embodiment of the invention, the propylene polymer (A1) componentcan have a 1% secant flexural modulus from a low of about 1000 MPa,about 1100 MPa, about 1200 MPa, about 1250 MPa, about 1300 MPa, about1400 MPa, or about 1,500 MPa to a high of about 1,800 MPa, about 2,100MPa, about 2,600 MPa, or about 3,000 MPa, as measured according to ASTMD 790 (A, 1.0 mm/min), preferably from about 1100 MPa to about 2,200MPa, about 1200 MPa to about 2,000 MPa, about 1400 MPa to about 2,000MPa, or about 1500 MPa or more. 1% Secant flexural modulus is determinedby using an ISO 37-Type 3 bar, with a crosshead speed of 1.0 mm/min anda support span of 30.0 mm via an Instron machine according to ASTM D 790(A, 1.0 mm/min).

In any embodiment of the invention, the propylene polymer compositionsproduced herein, particularly the composition produced after Stage A1and Stage A2 (the combined A1 & A2 components), preferably have a 1%secant flexural modulus from about 1000 MPa to about 3,000 MPa, about1500 MPa to about 3000 MPa, about 1800 MPa to about 2500 MPa, or about1800 MPa to about 2000 MPa.

In any embodiment of the invention, the propylene polymer (A1) componentcan have a melt flow rate (MFR, ASTM 1238, 230° C., 2.16 kg) from a lowof about 0.1 dg/min, about 0.2 dg/min, about 0.5 dg/min, about 1 dg/min,about 15 dg/min, about 30 dg/min, or about 45 dg/min to a high of about75 dg/min, about 100 dg/min, about 200 dg/min, or about 300 dg/min. Forexample, the polymer can have an MFR of about 0.5 dg/min to about 300dg/min, about 1 dg/min to about 300 dg/min, about 5 dg/min to about 150dg/min, about 10 dg/min to about 100 dg/min, or about 20 dg/min to about60 dg/min.

In any embodiment of the invention, the propylene polymer compositionsproduced herein, particularly the composition produced after Stage A1and Stage A2 (the combined A1& A2 components), can have an MFR (ASTM1238, 230° C., 2.16 kg) of from about 1 dg/min to about 300 dg/min,about 5 dg/min to about 150 dg/min, about 10 dg/min to about 100 dg/min,or about 20 dg/min to about 60 dg/min, preferably from about 50 to about200 dg/min, preferably from about 55 to about 150 dg/min, preferablyfrom about 60 to about 100 dg/min.

In any embodiment of the invention, the propylene polymer (A1) componentcan have an Mw (as measured by GPC-DRI) from 50,000 to 1,000,000 g/mol,alternately from 80,000 to 1,000,000 g/mol, alternately from 100,000 to800,000 g/mol, alternately from 200,000 to 600,000 g/mol, alternatelyfrom 300,000 to 550,000 g/mol, or alternately from 330,000 to 500,000g/mol.

In any embodiment of the invention, the propylene polymer compositionsproduced herein, particularly the composition produced after Stage A1and Stage A2 (the combined A1 & A2 components), can have an Mw (asmeasured by GPC-DRI) from 50,000 to 1,000,000 g/mol, alternately from80,000 to 1,000,000 g/mol, alternately from 100,000 to 800,000 g/mol,alternately from 200,000 to 600,000 g/mol, alternately from 300,000 to550,000 g/mol, or alternately from 330,000 to 500,000 g/mol.

In any embodiment of the invention, the propylene polymer (A1) componentcan have an Mw/Mn (as measured by GPC-DRI) of greater than 1 to 20, or1.1 to 15, or 1.2 to 10, or 1.3 to 5, or 1.4 to 4.

In any embodiment of the invention, the propylene polymer compositionsproduced herein, particularly the composition produced after Stage A1and Stage A2 (the combined A1 & A2 components), can have an Mw/Mn (asmeasured by GPC-DRI) of greater than 5 to 50, or 5.5 to 45, or 6 to 40,or 6.5 to 35, or 7 to 30.

In any embodiment of the invention, the propylene polymer compositionsproduced herein, particularly the composition produced after Stage A1and Stage A2 (the combined A1 & A2 components), can have a totalpropylene content of at least 75 wt %, at least 80 wt %, at least 85 wt%, at least 90 wt %, or at least 95 wt %, or 100 wt % based on theweight of the propylene polymer composition.

In any embodiment of the invention, the propylene polymer compositionsproduced herein, particularly the composition produced after Stage A1and Stage A2 (the combined A1 & A2 components), can have a totalco-monomer content from about 1 wt % to about 35 wt %, about 2 wt % toabout 30 wt %, about 3 wt % to about 25 wt %, or about 5 wt % to about20 wt %, based on the total weight of the propylene polymercompositions, with the balance being propylene.

In any embodiment of the invention, the propylene polymer compositionsproduced herein, particularly the composition produced after stage A1and stage A2 (the combined A1 & A2 components), can have a propylenemeso diads content of 90% or more, 92% or more, about 94% or more, orabout 96% or more. Polypropylene microstructure is determined accordingto the ¹³C NMR procedure described below.

In any embodiment of the invention, the propylene polymer compositionsproduced herein, particularly the composition produced after stage A1and stage A2 (the combined A1 & A2 components), can have a melting point(T_(m), DSC peak second melt) from at least 100° C. to about 175° C.,about 105° C. to about 170° C., about 110° C. to about 165° C., or about115° C. to about 155° C.

In any embodiment of the invention, the propylene polymer compositionsproduced herein, particularly the composition produced after stage A1and stage A2 (the combined A1 & A2 components), can have acrystallization point (Tc, DSC) of 115° C. or more, preferably from atleast 100° C. to about 150° C., about 105° C. to about 130° C., about110° C. to about 125° C., or about 115° C. to about 125° C.

In any embodiment of the invention, the propylene polymer compositionsproduced herein, particularly the composition produced after stage A1and stage A2 (the combined A1 & A2 components), can have a CDBI of 50%or more (preferably 60% or more, alternately 70% or more, alternately80% or more, alternately 90% or more, alternately 95% or more).

In any embodiment of the invention, the propylene polymer compositionsproduced herein, particularly the composition produced after stage A1and stage A2 (the combined A1 & A2 components), can have a multimodal(such as bimodal) MWD (Mw/Mn) distribution of polymer species.

In an embodiment, the propylene polymer composition produced herein has:

-   a) at least 50 mol % propylene (or from 50 to 100 mol %, or from 60    to 97 mol %, or from 65 to 95 mol %, or from 70 to 90 mol %, or at    least 90 mol %, or from 50 to 99 mol %) and optionally at least 1    mol % co-monomer (or from 1 to 50 mol %, or from 3 to 40 mol %, or    from 5 to 35 mol %, or from 10 to 30 mol %) based upon the weight of    the propylene polymer composition; and/or-   b) a 1% secant flexural modulus of at least 1000 MPa (or at least    1300 MPa, or at least 1500 MPa, or at least 1600 MPa, or at least    1800 MPa, or at least 1900 MPa, or at least 2000 MPa, or at least    2100 MPa, or at least 2200 MPa);-   c) less than 200 regio defects (sum of 2,1-erythro and 2,1-threo    insertions and 3,1-isomerizations) per 10,000 propylene units, as    determined by ¹³C NMR spectroscopy (or from 5 to 200, or from 10 to    200, or from 15 to 200, or from 17 to 175 regio defects per 10,000    propylene units, alternatively more than 5, or 10, or 20, or 30, or    40, but less than 200 regio defects, alternatively less than 150    regio defects per 10,000 propylene units); and/or-   d) a porosity greater than or equal to about 15%, based on the total    volume of the propylene polymer base resin or matrix, determined by    mercury infiltration porosimetry (or greater than or equal to 20,    25, 30, 35, 40, 45%, up to about 50, 60, 70, 80 or 85% or higher);    and/or-   e) a median PD as determined by mercury intrusion porosimetry of    less than 165 μm or less than 160 μm (or from 1, or 2, or 5, or 10    μm up to 50, or 60, or 70, or 80, or 90, or 100, or 120, or 125, or    150, or 160, or 165 μm); and/or-   f) an Mw/Mn of at least 2, at least 3, at least 4, or at least 5, as    determined GPC-DRI (or from 5 to 40, or from 6 to 20, or from 7 to    15); and/or-   g) a melt flow rate of 50 dg/min or more, as determined by ASTM D    1238, 230° C., 2.16 kg (or 60 dg/min or more, or 75 dg/min or more);    and/or-   h) a multimodal Mw/Mn, as determined by GPC-DRI, particularly the    composition produced after stage A and stage B (the combined A&B    components), or (ii) an Mw/Mn of greater than 1 to 5 (alternately    1.1 to 3, alternately 1.3 to 2.5), particularly the composition    produced after stage A;-   i) a multimodal PSD; and/or-   j) if co-monomer is present, a CDBI of 50% or more (or 60% or more,    alternately 70% or more, alternately 80% or more, alternately 90% or    more, alternately 95% or more).

In any embodiment described herein, propylene copolymer composition mayhave a melting point (Tm, DSC peak second melt) from at least 100° C. toabout 175° C., about 105° C. to about 170° C., about 110° C. to about165° C., or about 115° C. to about 155° C., and a crystallization point(Tc, DSC peak second melt) of 115° C. or more, preferably from at least100° C. to about 150° C., about 105° C. to about 130° C., about 110° C.to about 125° C., or about 115° C. to about 125° C.

Heterophasic Copolymers: In some embodiments of the invention, thepropylene polymer is heterophasic. In some further embodiments of theinvention the propylene polymer is an impact copolymer (ICP). In someembodiments, the ICP comprises a blend of iPP (component A or thecomposition produced after stage A1 and optionally stage A2 (thecombined A1 & A2 components) described above), preferably with a T_(m)of 120° C. or more, with a propylene polymer with a glass transitiontemperature (T_(g)) of −30° C. or less and/or an ethylene polymer(component B). In the following ICP embodiments of the invention,component A refers to the composition produced after stage A discussedin the preceding polymer product embodiments, as well as the compositionproduced after stage A1 and stage A1 and stage A2 (the combined A1 & A2components) described above.

In some embodiments, component A (or the combined A1 & A2 component ifpresent) comprises 60 to 95 wt % of the ICP, and component B 5 to 40 wt%, by total weight of components A (or the combined A1 & A2 component ifpresent) and B, or by total weight of the ICP. The iPP of component A(or the combined A1 & A2 component if present) may have any one,combination or all of the properties of any of the iPP embodimentsdisclosed herein, and/or may be made by any of the processes describedherein for producing iPP. In some embodiments of the invention,component B is an ethylene copolymer or an EP rubber, preferably with aT_(g) of −30° C. or less. In some embodiments of the invention thematrix phase is comprised primarily of component A (or the combined A1 &A2 component if present), while component (B) primarily comprises thedispersed phase or is co-continuous. In some embodiments of theinvention, the ICP comprises only two monomers: propylene and a singleco-monomer chosen from among ethylene and C₄ to C₈ alpha-olefins,preferably ethylene, butene, hexene or octene, more preferably ethylene.Alternately or additionally, the ICP comprises three monomers: propyleneand two co-monomers chosen from among ethylene and C₄ to C₈alpha-olefins, preferably two selected from ethylene, butene, hexene andoctene. Preferably, component A (or the combined A&B component ifpresent) has a T_(m) of 120° C. or more, or 130° C. or more, or 140° C.or more, or 150° C. or more, or 160° C. or more). Preferably, componentC has a T_(g) of −30° C. or less, or −40° C. or less, or −50° C. orless.

In an embodiment of the invention, the (B) component has a heat offusion (Hf) of 90° C. or less (as determined by DSC). Preferably the (B)component has an Hf of 70° C. or less, preferably 50° C. or less,preferably 35° C. or less.

Preferably the ICP produced from Stages A, combined A1 & A2, and/or B isheterophasic, especially wherein the iPP is a continuous phase and thefill rubber is a dispersed or co-continuous phase.

In embodiments, the impact copolymer has a matrix phase comprisingprimarily a propylene polymer composition having a melting point (T_(m))of 100° C. or more, an MWD of 5 or more and a multimodal MWD, and thedispersed or fill phase comprises (preferably primarily comprises) apolyolefin having a T_(g) of −20° C. or less. Preferably, the matrixphase comprises primarily homopolymer polypropylene (hPP) and/or randomcopolymer polypropylene (RCP) with relatively low co-monomer content(less than 5 wt %), and has a melting point of 110° C. or more(preferably 120° C. or more, preferably 130° C. or more, preferably 140°C. or more, preferably 150° C. or more, preferably 160° C. or more).Preferably, the dispersed phase comprises primarily one or more ethyleneor propylene copolymer(s) with relatively high co-monomer content (atleast 5 wt %, preferably at least 10 wt %); and has a T_(g) of −30° C.or less (preferably −40° C. or less, preferably −50° C. or less).

An “in-situ ICP” is a specific type of ICP which is a reactor blend ofthe (A) and (B) components of an ICP, meaning (A) optionally (A1 & A2)and (C) were made in separate reactors (or reactions zones) physicallyconnected in series, with the effect that an intimately mixed finalproduct is obtained in the product exiting the final reactor (orreaction zone). Typically, the components are produced in a sequentialpolymerization process, wherein (A1) is produced in a first reactor istransferred to a second reactor where optionally (A2) is produced in asecond reactor (or the combined A1 & A2 components may be produced inone reactor), and the product is transferred to another reactor where(B) is produced and incorporated into the (A or A1 & A2) matrix. Theremay also be a minor amount of a component (C), produced as a byproductduring this process, comprising primarily the non-propylene co-monomer(e.g., (C) will be an ethylene polymer if ethylene is used as theco-monomer). In the literature, especially in the patent literature, anin-situ ICP is sometimes identified as “reactor-blend ICP” or a “blockcopolymer”, although the latter term is not strictly accurate sincethere is at best only a very small fraction of molecules that are (A)(C)copolymers. In a preferred embodiment of the invention, the polymercomposition produced herein is an in-situ-ICP.

An “ex-situ ICP” is a specific type of ICP which is a physical blend of(A) and optionally (A1 & A2) and (B), meaning (A) (A1 & A2) and/or (B)were synthesized independently and then subsequently blended typicallyusing a melt-mixing process, such as an extruder. An ex-situ ICP isdistinguished by the fact that (A) and or (A1 & A2), and (B) arecollected in solid form after exiting their respective synthesisprocesses, and then combined; whereas for an in-situ ICP, (A) optionally(A1 & A2) and (B) are combined within a common synthesis process andonly the blend is collected in solid form.

In one or more embodiments, the impact copolymer (the combination of A,optional A1 & A2 and B components) advantageously has more than 15 andless than 200 regio defects (defined as the sum of 2,1-erythro and2,1-threo insertions, and 3,1-isomerizations) per 10,000 propyleneunits, alternatively more than 17 and less than 175 regio defects per10,000 propylene units, alternatively more than 20, or 30, or 40, butless than 200 regio defects, alternatively less than 150 regio defectsper 10,000 propylene units. The regio defects are determined using ¹³CNMR spectroscopy as described below.

The impact polymers produced typically have a heterophasic morphologysuch that the matrix phase is primarily propylene polymer having a Tm of120° C. or more and the dispersed phase is primarily an ethylenecopolymer (such as EP Rubber) or propylene polymer typically having a Tgof −30° C. or less.

The impact copolymers produced herein preferably have a total propylenecontent of at least 50 wt %, at least 75 wt %, at least 80 wt %, atleast 85 wt %, at least 90 wt %, or at least 95 wt %, or 100 wt % basedon the weight of the propylene polymer composition.

The impact copolymers produced herein preferably have a total co-monomercontent from about 0.1 wt % to about 75 wt %, about 1 wt % to about 35wt %, about 2 wt % to about 30 wt %, about 3 wt % to about 25 wt %, orabout 5 wt % to about 20 wt %, based on the total weight of thepropylene polymer compositions, with the balance being propylene.

In embodiments, impact copolymers comprise iPP (typically from stage Aor A1 & A2) and ethylene copolymer (typically from stage B) andtypically have an ethylene copolymer (preferably ethylene propylenecopolymer, preferably EP rubber) content in a range from a low of about5 wt %, about 8 wt %, about 10 wt %, or about 15 wt %, or about 20 wt %,or about 30 wt %, or about 40 wt %, or about 50 wt %, to any higherupper limit of about 25 wt %, about 30 wt %, about 35 wt %, or about 40wt %, or about 50 wt %, or about 60 wt %, or about 70 wt %, or about 75wt %, or about 80 wt %, or about 85 wt % or higher. For example, theimpact polymer can have an ethylene copolymer content of about 15 wt %to about 85 wt %, about 30 wt % to about 75 wt %, about 35 wt % to about70 wt %, or about 40 wt % to about 60 wt %. In some preferredembodiments of the invention, the ICP has an ethylene copolymer contentof at least about 25 wt %, at least about 30 wt %, at least about 35 wt%, or at least about 40 wt %, up to a high of about 50 wt %, 60 wt %, 70wt %, 80 wt %, or higher.

In embodiments, impact copolymers comprise iPP (from stage A or A1 & A2)and ethylene copolymer (from stage B), the impact copolymer can have apropylene content in the ethylene copolymer component from a low ofabout 25 wt %, about 85 wt % or higher, or to about 37 wt %, or about 46wt % to a high of about 73 wt %, or about 77 wt %, or about 80 wt %,based on the weight of the ethylene copolymer. For example, the impactcopolymer can have a propylene content of the ethylene copolymercomponent from about 25 wt % to about 80 wt %, about 10 wt % to about 75wt %, about 35 wt % to about 70 wt %, or at least 40 wt % to about 80 wt%, based on the weight of the ethylene copolymer.

The impact copolymers produced herein preferably have a heat of fusion(H_(f), DSC second heat) of 60 J/g or more, 70 J/g or more, 80 J/g ormore, 90 J/g or more, about 95 J/g or more, or about 100 J/g or more.

In embodiments, the impact polymers produced herein have a 1% secantflexural modulus greater than about 300 MPa, or 500 MPa, or 700 MPa, or1000 MPa, or 1500 MPa, or 2000 MPa, or from about 300 MPa to about 3,000MPa, about 500 MPa to about 2,500 MPa, about 700 MPa to about 2,000 MPa,or about 900 MPa to about 2,000 MPa, as measured according to ASTM D 790(A, 1.0 mm/min).

In embodiments, the impact polymers produced herein may have an Mw (asmeasured by GPC-DRI) from 50,000 to 1,000,000 g/mol, alternately from80,000 to 1,000,000 g/mol, alternately 100,000 to 800,000 g/mol,alternately 200,000 to 600,000 g/mol, alternately from 300,000 to550,000 g/mol, or alternately from 330,000 to 500,000 g/mol.

¹³C-NMR Spectroscopy on Polyolefins: Polypropylene microstructure isdetermined by ¹³C-NMR spectroscopy, including the concentration ofisotactic and syndiotactic diads ([m] and [r]), triads ([mm] and [rr]),and pentads ([mmmm] and [rrrr]). The designation “m” or “r” describesthe stereochemistry of pairs of contiguous propylene groups, “m”referring to meso and “r” to racemic. Samples are dissolved ind2-1,1,2,2-tetrachloroethane at 120° C., and spectra are acquired with a10-mm broadband probe recorded at 120° C. using a 400 MHz (or higher)NMR spectrometer (such as Varian Inova 700 or Unity Plus 400, in eventof conflict the 700 shall be used). Polymer resonance peaks arereferenced to mmmm=21.83 ppm. Calculations involved in thecharacterization of polymers by NMR are described by F. A. Bovey inPolymer Conformation and Configuration (Academic Press, New York 1969)and J. Randall in Polymer Sequence Determination, ¹³C NMR Method(Academic Press, New York, 1977).

Regio Defect Concentrations by ¹³C NMR: ¹³Carbon NMR spectroscopy isused to measure stereo and regio defect concentrations in thepolypropylene. ¹³Carbon NMR spectra are acquired with a 10-mm broadbandprobe on a Varian Inova 700 or UnityPlus 400 spectrometer (in event ofconflict the 700 shall be used). The samples were prepared in1,1,2,2-tetrachloroethane-d2 (TCE). Sample preparation (polymerdissolution) was performed at 120° C. In order to optimize chemicalshift resolution, the samples were prepared without chromiumacetylacetonate relaxation agent. Signal-to-noise was enhanced byacquiring the spectra with nuclear Overhauser enhancement for 10 secondsbefore the acquisition pulse, and 3.2 second acquisition period, for anaggregate pulse repetition delay of 14 seconds. Free induction decays of3400-4400 coadded transients were acquired at a temperature of 120° C.After Fourier transformation (256 K points and 0.3 Hz exponential linebroadening), the spectrum is referenced by setting the dominant mmmmmeso methyl resonance to 21.83 ppm.

Chemical shift assignments for the stereo defects (given as stereopentads) can be found in the literature [L. Resconi, L. Cavallo, A.Fait, and F. Piemontesi, Chem. Rev. 2000, 100, pp. 1253-1345]. Thestereo pentads (e.g., mmmm, mmmr, mrrm, etc.) can be summedappropriately to give a stereo triad distribution (mm, mr, and rr), andthe mole percentage of stereo diads (m and r). Three types of regiodefects were quantified: 2,1-erythro, 2,1-threo, and 3,1-isomerization.The structures and peak assignments for these are also given in Chem.Rev. 2000, 100, pp. 1253-1345. The concentrations for all defects arequoted in terms of defects per 10,000 monomer units.

The regio defects each give rise to multiple peaks in the carbon NMRspectrum, and these are all integrated and averaged (to the extent thatthey are resolved from other peaks in the spectrum), to improve themeasurement accuracy. The chemical shift offsets of the resolvableresonances used in the analysis are tabulated below. The precise peakpositions may shift as a function of NMR solvent choice.

Regio defect Chemical shift range (ppm) 2,1-erythro 42.3, 38.6, 36.0,35.9, 31.5, 30.6, 17.6, 17.2 2,1-threo 43.4, 38.9, 35.6, 34.7, 32.5,31.2, 15.4, 15.0 3,1 insertion 37.6, 30.9, 27.7

The average integral for each defect is divided by the integral for oneof the main propylene signals (CH₃, CH, CH₂), and multiplied by 10,000to determine the defect concentration per 10,000 monomer units.

Ethylene content in ethylene copolymers is determined by ASTM D 5017-96,except that the minimum signal-to-noise should be 10,000:1. Propylenecontent in propylene copolymers is determined by following the approachof Method 1 in Di Martino and Kelchermans, J. Appl. Polym. Sci., 56, p.1781, (1995), and using peak assignments from Zhang, Polymer, 45, p.2651 (2004) for higher olefin co-monomers.

Composition Distribution Breadth index (CDBI) is a measure of thecomposition distribution of monomer within the polymer chains. It ismeasured as described in WO 93/03093, specifically columns 7 and 8 aswell as in Wild et al, J. Poly. Sci., Poly. Phys. Ed., Vol. 20, p. 441,(1982) and U.S. Pat. No. 5,008,204, including that fractions having Mwbelow 15,000 g/mol are ignored when determining CDBI.

Unless otherwise indicated, Tg is determined by DMA, according to theprocedure set out in US 2008/0045638 at page 36, including anyreferences cited therein.

Embodiments Listing

The present invention provides, among others, the following embodiments,each of which may be considered as optionally including any alternateembodiments.

-   E1. A heterophasic propylene copolymer comprising:-   a matrix phase comprising:-   at least 50 mol % propylene;-   a 1% Secant flexural modulus of at least 1000 MPa, determined    according to ASTM D 790 (A, 1.0 mm/min);-   less than 200 regio defects (alternately between greater than 5 and    less than 200 regio defects) per 10,000 propylene units, determined    by ¹³C NMR;-   a multimodal (alternately bimodal) molecular weight distribution;-   if comonomer is present, a composition distribution breadth index    (CDBI) of 50% or more; and-   a fill phase at least partially filling pores in the matrix phase,    wherein the fill phase comprises at least 15 wt % of the    heterophasic propylene copolymer, based on the total weight of the    matrix and fill phases.-   E2. The heterophasic propylene copolymer of Embodiment E1, wherein    the fill phase comprises 20 wt % or more (alternately 25 wt % or    more, or 30 wt % or more, or 35 wt % or more, or 40 wt % or more; up    to 85 wt %, or up to 80 wt %, or up to 75 wt %, or up to 70 wt %, or    up to 60 wt %, or up to 50 wt %) of the heterophasic copolymer,    based on the total weight of the matrix and fill phases.-   E3. The heterophasic propylene copolymer of Embodiment E1 or    Embodiment E2, wherein the matrix phase comprises a median pore    diameter (PD) greater than 0.1 μm (alternately greater than 1 μm, or    greater than 2 μm, or greater than 5 μm, or greater than 6 μm, or    greater than 8 μm, or greater than 10 μm, or greater than 12 μm, or    greater than 15 μm, or greater than 20 μm) and/or less than 165 μm    (alternately less than 50 μm, or less than 60 μm, or less than 70    μm, or less than 80 μm, or less than 90 μm, or less than 100 μm, or    less than 120 μm, or less than 125 μm, or less than 140 μm, or less    than 150 μm, or less than 160 μm) (alternately from 6 μm up to 160    μm or from 8 μm up to 150 μm).-   E4. The heterophasic propylene copolymer of any one of the preceding    embodiments, wherein the matrix phase has a multimodal (alternately    bimodal) MWD comprising relatively high and low molecular weight    modes, wherein a high molecular weight mode comprises at least about    80 wt % and a low molecular weight mode comprises at least about 1    wt % (alternately at least about 2 wt %, at least about 3 wt %, at    least about 5 wt %, at least about 10 wt %), based on the total    weight of the matrix phase.-   E5. The heterophasic propylene copolymer of any one of the preceding    embodiments, wherein the polymer is in a particulated form.-   E6. The heterophasic propylene copolymer of any one of the preceding    embodiments, wherein at least 90% (alternately at least 95%, or at    least 98%, or at least 99%) by volume has a particle size (PS)    greater than about 120 μm (alternately from 150, 200, 300, 400, or    500 μm up to 10, 5, or 1 mm).-   E7. The heterophasic propylene copolymer of any one of the preceding    embodiments, wherein the fill phase comprises a polyolefin having a    Tg of −20° C. or less (alternately −30° C. or less, or −40° C. or    less, or −50° C. or less) determined by DSC.-   E8. The heterophasic propylene copolymer of any one of the preceding    embodiments, wherein the fill phase comprises ethylene and from    about 3 wt % to 85 wt % (alternately from about 5 wt, or about 8 wt    %, or about 10 wt %, or about 15 wt %, or about 20 wt %, or about 30    wt %, or about 40 wt %, or about 50 wt %, up to about 25 wt %, or    about 30 wt %, or about 35 wt %, or about 40 wt %, or about 50 wt %,    or about 60 wt %, or about 70 wt %, or about 75 wt %, or about 80 wt    %) of one or more C₃ to C₂₀ alpha olefins, based on the weight of    the fill phase.-   E9. The heterophasic propylene copolymer of any one of the preceding    embodiments, wherein the fill phase comprises ethylene propylene    rubber.-   E10. The heterophasic propylene copolymer of any one of the    preceding embodiments, comprising an overall molecular weight    distribution of 5 or more (alternately from 5 to 20).-   E11. The heterophasic propylene copolymer of any one of the    preceding embodiments, wherein the polymer is made with a single    site catalyst system.-   E12. The heterophasic propylene copolymer of Embodiment E11, wherein    the single site catalyst system comprises a single site catalyst    precursor compound, an activator for the precursor compound, and a    support.-   E13. The heterophasic propylene copolymer of Embodiment E11 or    Embodiment E12, wherein the catalyst system comprises a single site    catalyst precursor compound, an activator for the precursor    compound, and a support, the support having a specific surface area    (SA) of 400 m²/g or more (alternately 400-1000 m²/g, or 400-650    m²/g, or 650-1000 m²/g), a pore volume (PV) of from 0.5 to 2 mL/g    (alternately 0.5 to 1.5 mL/g, or 1.1 to 1.6 mL/g), and a mean PD of    from 1 to 20 nm (10 to 200 Å) (alternately 1 to 7 nm, or 7 to 20    nm).-   E14. The heterophasic propylene copolymer of any one of the    preceding embodiments, wherein the matrix is comprised of a    plurality of polymer subglobules defining interstitial spaces    comprising the fill phase.-   E15. The heterophasic propylene copolymer of any one of the    preceding embodiments, further comprising a total propylene content    of at least 75 wt % (alternately at least 80 wt %, at least 85 wt %,    at least 90 wt %, or at least 95 wt %, or 100 wt %) based on the    weight of the heterophasic propylene copolymer composition.-   E16. The heterophasic propylene copolymer of any one of the    preceding embodiments, further comprising a total comonomer content    from about 1 wt % to about 35 wt % (alternately about 2 wt % to    about 30 wt %, or about 3 wt % to about 25 wt %, or about 5 wt % to    about 20 wt %) based on the total weight of the heterophasic    propylene copolymer composition.-   E17. The heterophasic propylene copolymer of any one of the    preceding embodiments, wherein the fill phase comprises a CDBI of    50% or more (alternately 60% or more, 70% or more, 80% or more, 90%    or more, or 95% or more).-   E18. The heterophasic propylene copolymer of any one of the    preceding embodiments, further comprising at least 10% isotactic    pentads (alternately at least 20% isotactic pentads, or at least 30%    isotactic pentads, or at least 40% isotactic pentads, or at least    50% isotactic pentads).-   E19 The heterophasic propylene copolymer of any one of the preceding    embodiments, further comprising more than 5 (alternately more than    10, or more than 15, or more than 17, or more than 20, or more than    30, or more than 40) regio defects per 10,000 propylene units, as    determined by ¹³C NMR.-   E20. The heterophasic propylene copolymer of any one of the    preceding embodiments, further comprising less than 200 regio    defects (alternatively less than 175 or less than 150) per 10,000    propylene units.-   E21. The heterophasic propylene copolymer of any one of the    preceding embodiments, wherein the 1% Secant flexural modulus is at    least 1300 MPa (alternately at least 1500 MPa, or at least 1700 MPa,    or at least 1800 MPa, or at least 1900 MPa, or at least 2000 MPa, or    at least 2100 MPa, or at least 2200 MPa), determined according to    ASTM D 790 (A, 1.0 mm/min).-   E22. The heterophasic propylene copolymer of any one of the    preceding embodiments, wherein the matrix phase comprises a melting    point (Tm, DSC peak second melt) of at least 100° C. or more    (alternately 120° C. or more, 130° C. or more, or 140° C. or more,    or 150° C. or more, or 160° C. or more).-   E23. The heterophasic propylene copolymer of any one of the    preceding embodiments, wherein the matrix phase comprises an Mw/Mn    as measured by GPC-DRI of greater than 1 (alternately 1.1, or 1.2,    or 1.3, or 1.4) to 20 (alternately 15, or 10, or 5, or 4).-   E24. The heterophasic propylene copolymer of any one of the    preceding embodiments, comprising a multimodal (alternately bimodal)    molecular weight distribution with an overall Mw/Mn of greater than    1 to 20 and at least one mode having an Mw/Mn of greater than 1 to    5.-   E25. The heterophasic propylene copolymer of any one of the    preceding embodiments, comprising a heat of fusion (H_(f), DSC    second heat) of 60 J/g or more (alternately 70 J/g or more, 80 J/g    or more, 90 J/g or more, about 95 J/g or more, or about 100 J/g or    more).-   E26. The heterophasic propylene copolymer of any one of the    preceding embodiments, further comprising a melt flow rate (MFR,    ASTM 1238, 230° C., 2.16 kg) from about 0.1 dg/min (alternately from    about 0.2 dg/min, about 0.5 dg/min, about 1 dg/min, about 15 dg/min,    about 30 dg/min, or about 45 dg/min) up to about 300 dg/min    (alternately about 75 dg/min, about 100 dg/min, about 200 dg/min).-   E27. The heterophasic propylene copolymer of any one of the    preceding embodiments, further comprising an Mw (as measured by    GPC-DRI) from 50,000 g/mol (alternately 80,000 g/mol, 100,000 g/mol,    200,000 g/mol, 300,000 g/mol, or 330,000 g/mol) to 1,000,000 g/mol    (alternately 800,000 g/mol, 600,000 g/mol, 550,000 g/mol, or 500,000    g/mol).-   E28. The heterophasic propylene copolymer of any one of the    preceding embodiments, wherein the matrix phase comprises relatively    large and small particle size modes, wherein the large particle size    mode comprises at least about 80 vol % and the low molecular weight    mode comprises at least about 1 vol % (alternately at least about 2    vol %, at least about 3 vol %, at least about 5 vol %), based on the    total volume of the heterophasic propylene copolymer.-   E29. The heterophasic propylene copolymer of any one of the    preceding embodiments, comprising relatively large and small    particle size modes, wherein the large particle size mode comprises    at least about 80 vol % and the low molecular weight mode comprises    at least about 1 vol % (alternately at least about 2 vol %, at least    about 3 vol %, at least about 5 vol %), based on the total volume of    the heterophasic propylene copolymer.-   E30. The heterophasic propylene copolymer of Embodiment E28 or    Embodiment E29, wherein the large particle size mode is 120 μm or    larger (alternately 150 μm or larger, 200 μm or larger, 300 μm or    larger, 400 μm or larger, or 500 μm or larger).-   E31. A process to polymerize propylene comprising:-   (a) contacting propylene monomer under polymerization conditions    with a first catalyst system, the catalyst system comprising a    single site catalyst precursor compound, an activator, and a    support, wherein the support has an average PS of more than 30 μm,    an SA of 400 m²/g or more, a PV of from 0.5 to 2 mL/g (alternately    0.5 to 1.5 mL/g or 1.1 to 1.6 mL/g), and a mean PD of from 1 to 20    nm (10 to 200 Å), as determined by BET nitrogen adsorption, to form    a matrix phase of propylene polymer comprising at least 50 mol %    propylene and a porosity of 15% or more as determined by mercury    intrusion porosimetry; and-   (b) contacting an alpha olefin monomer selected from ethylene, C₃ to    C₂₀ alpha olefins, or a combination thereof, including at least one    alpha olefin other than propylene, with a second catalyst system    under polymerization conditions to form a fill phase for pores of    the matrix, wherein the second catalyst system comprises a    metallocene catalyst precursor compound, an activator, and a    support, and wherein the second catalyst system comprises,    compositionally, the same or different single site catalyst    precursor compound as in the first catalyst system, the same or    different activator as in the first catalyst system, the same or    different support as in the first catalyst system, or any    combination thereof.-   E32. The process of Embodiment E31, wherein (1) the polymerization    of the alpha olefin monomer in (b) is in the presence of the matrix    phase from (a), (2) the polymerization of the propylene monomer with    the first catalyst system in (a) is in the presence of the fill    phase from (b), or (3) a combination thereof.-   E33. The process of Embodiment E32, wherein the contacting in (a)    comprises polymerizing the propylene monomer for a time period, A1,    optionally increasing a concentration of hydrogen or other chain    termination agent in the polymerization after time period A1 and    polymerizing the propylene in the presence of the hydrogen or other    chain transfer agent for a time period, A2, wherein a time period A    equals the sum of time periods A1 and A2, and the contacting in (b)    comprises polymerizing the alpha olefin monomer for a time period,    B, after time period A.-   E34. The process of Embodiment E33, wherein time period A2 is    greater than zero.-   E35. The process of Embodiment E34, wherein time period A1 is at    least as long as time period A2, and wherein the concentration of    the hydrogen or other chain transfer agent during time period A2 is    at least three times greater than the concentration of the hydrogen    or other chain transfer agent in time period A1.-   E36. The process of any one of embodiments E31 to E35, wherein the    alpha olefin monomer comprises ethylene and from about 3 wt % to 85    wt % (alternately from about 5 wt, or about 8 wt %, or about 10 wt    %, or about 15 wt %, or about 20 wt %, or about 30 wt %, or about 40    wt %, or about 50 wt %, up to about 25 wt %, or about 30 wt %, or    about 35 wt %, or about 40 wt %, or about 50 wt %, or about 60 wt %,    or about 70 wt %, or about 75 wt %, or about 80 wt %) of the one or    more C₃ to C₂₀ alpha olefins, based on the weight of the alpha    olefin monomer.-   E37. The process of any one of embodiments E31 to E36, wherein the    propylene monomer in (a) is essentially free of ethylene and C₄ to    C₂₀ alpha olefins, and the propylene polymer formed after time    period A is a propylene homopolymer.-   E38. The process of any one of embodiments E31 to E37, wherein the    first catalyst system has a multimodal (alternately bimodal)    particle size distribution.-   E39. The process of Embodiment E38, wherein a larger one of the    first catalyst system modes comprises at least about 80 vol % and a    smaller one of the catalyst system modes comprises at least about 1    vol % (alternately at least about 2 vol %, at least about 3 vol %,    at least about 5 vol %), based on the total volume of the first    catalyst system.-   E40. The process of any one of embodiments E31 to E39, wherein the    support comprises agglomerates of a plurality of primary particles    wherein the primary particles have a smaller average particle size    relative to the agglomerates.-   E41. The process of embodiment E40, wherein the primary particles    having an average particle size from 1 nm to 50 μm (alternately 1 μm    to 50 μm).-   E42. The process of Embodiment E40 or Embodiment E41, further    comprising fragmenting (alternately disagglomerating) the    agglomerates to disperse catalyst sites in the propylene polymer    matrix.-   E43. The process of any one of embodiments E31 to E42, wherein the    second catalyst system comprises fragments from the first catalyst    system.-   E44. The process of any one of embodiments E31 to E43, wherein the    support of the first catalyst system comprises metal oxide.-   E45. The process of any one of embodiments E31 to E44, wherein the    support of the first catalyst system comprises silica.-   E46. The process of any one of embodiments E31 to E45, wherein the    support of the first catalyst system is spray dried.-   E47. The process of any one of embodiments E31 to E46, wherein the    support of the first catalyst system has an average PS of more than    30 μm (alternately more than 40 μm, more than 50 μm, or more than 60    μm, or more than 65 μm, or more than 70 μm, or more than 75 μm, or    more than 80 μm, or more than 85 μm, or more than 90 μm, or more    than 100 μm, or more than 120 μm) up to 200 μm (alternately less    than 180 μm, or less than 160 μm, or less than 150 μm, or less than    130 μm).-   E48. The process of any one of embodiments E31 to E47, wherein the    support of the first catalyst system comprises SA less than 1400    m²/g (alternately less than 1200 m²/g, or less than 1100 m²/g, or    less than 1000 m²/g, or less than 900 m²/g, or less than 850 m²/g,    or less than 800 m²/g, or less than 750 m²/g, or less than 700 m²/g,    or less than 650 m²/g; and/or more than 500 m²/g, or more than 600    m²/g, or more than 650 m²/g, or more than 700 m²/g).-   E49. The process of any one of embodiments E31 to E48, wherein the    support of the first catalyst system comprises a mean PD greater    than 2 nm (alternately greater than 3 nm, or greater than 4 nm, or    greater than 5 nm, or greater than 6 nm, or greater than 7 nm, or    greater than 8 nm; and/or less than 20 nm, or less than 15 nm, or    less than 13 nm, or less than 12 nm, or less than 10 nm, or less    than 8 nm, or less than 7 nm, or less than 6 nm).-   E50. The process of any one of embodiments E31 to E49, wherein the    support of the first catalyst system comprises SA greater than 650    m²/g and mean PD less than 7 nm (70 Å).-   E51. The process of any one of embodiments E31 to E50, wherein the    support of the first catalyst system comprises SA less than 650 m²/g    or the mean PD is greater than 7 nm (70 Å).-   E52 The process of any one of embodiments E31 to E51, wherein the    activator of the first catalyst system comprises alumoxane    (alternately MAO or MMAO).-   E53. The process of any one of embodiments E31 to E52, wherein the    first catalyst system further comprises a co-activator selected from    the group consisting of: trialkylaluminum, dialkylmagnesium,    alkylmagnesium halide, and dialkylzinc (alternately selected from    the group consisting of: trimethylaluminum, triethylaluminum,    triisobutylaluminum, trihexylaluminum, tri-n-octylaluminum,    dimethylmagnesium, diethylmagnesium, dipropylmagnesium,    diisopropylmagnesium, dibutyl magnesium, diisobutylmagnesium,    dihexylmagnesium, dioctylmagnesium, methylmagnesium chloride,    ethylmagnesium chloride, propylmagnesium chloride,    isopropylmagnesium chloride, butyl magnesium chloride,    isobutylmagnesium chloride, hexylmagnesium chloride, octylmagnesium    chloride, methylmagnesium fluoride, ethylmagnesium fluoride,    propylmagnesium fluoride, isopropylmagnesium fluoride, butyl    magnesium fluoride, isobutylmagnesium fluoride, hexylmagnesium    fluoride, octylmagnesium fluoride, dimethylzinc, diethylzic,    dipropylzinc, and dibutylzinc) (alternately selected from the group    consisting of: trimethylaluminum, triethylaluminum,    triisobutylaluminum, tri-n-octylaluminum, trihexylaluminum, and    diethylzinc).-   E54. The process of any one of embodiments E31 to E53, wherein the    single site catalyst precursor compound is represented by the    following formula:    (Cp)mRAn M⁴Qk    wherein:-   each Cp is a cyclopentadienyl moiety or a substituted    cyclopentadienyl moiety substituted by one or more hydrocarbyl    radicals having from 1 to 20 carbon atoms;-   RA is a structural bridge between two Cpmoieties;-   M⁴ is a transition metal selected from groups 4 or 5;-   Q is a hydride or a hydrocarbyl group having from 1 to 20 carbon    atoms or an alkenyl group having from 2 to 20 carbon atoms, or a    halogen;-   m is 1, 2, or 3, with the proviso that if m is 2 or 3, each Cp may    be the same or different;-   n is 0 or 1, with the proviso that n=0 if m=1; and-   k is such that k+m is equal to the oxidation state of M⁴, with the    proviso that if k is greater than 1, each Q may be the same or    different.-   E55. The process of any one of embodiments E31 to E53, wherein the    single site catalyst precursor compound is represented by the    formula:    RA(CpR″p)(CpR*q)M⁵Qr    wherein:-   each Cp is a cyclopentadienyl moiety or substituted    cyclopentadienylmoiety;-   each R* and R″ is a hydrocarbyl group having from 1 to 20 carbon    atoms and may be the same or different;-   p is 0, 1, 2, 3, or 4;-   q is 1, 2, 3, or 4;-   R^(A) is a structural bridge between the Cp moieties imparting    stereorigidity to the metallocene compound;-   M⁵ is a group 4, 5, or 6 metal;-   Q is a hydrocarbyl radical having 1 to 20 carbon atoms or is a    halogen;-   r is s minus 2, where s is the valence of M5;-   wherein (CpR*q) has bilateral or pseudobilateral symmetry; R*q is    selected such that (CpR*q) forms a fluorenyl, alkyl substituted    indenyl, or tetra-, tri-, or dialkyl substituted cyclopentadienyl    radical; and (CpR″p) contains a bulky group in one and only one of    the distal positions;-   wherein the bulky group is of the formula AR^(W) _(V); and-   where A is chosen from group 4 metals, oxygen, or nitrogen, and Rw    is a methyl radical or phenyl radical, and v is the valence of A    minus 1.-   E56. The process of any one of embodiments E31 to E53, wherein the    single site catalyst precursor compound is represented by the    formula:

-   where:-   M is a group 4, 5 or 6 metal;-   T is a bridging group;-   each X is, independently, an anionic leaving group;-   each R², R³, R⁴, R⁵, R⁶, R⁷, R⁸, R⁹, R¹⁰, R¹¹, R¹², and R¹³ is,    independently, halogen atom, hydrogen, hydrocarbyl, substituted    hydrocarbyl, halocarbyl, substituted halocarbyl, silylcarbyl,    substituted silylcarbyl, germylcarbyl, substituted germylcarbyl    substituent or an —NR′₂, —SR′, —OR′, —OSiR′₃ or —PR′₂ radical,    wherein R′ is one of a halogen atom, a C₁-C₁₀ alkyl group, or a    C₆-C₁₀ aryl group.-   E57. The process of Embodiment E56, wherein at least one of R², R³,    R⁴, R⁵, R⁶, R⁷, R⁸, R⁹, R¹⁰, R¹¹, R¹², and R¹³ is a cyclopropyl    substituent represented by the formula:

-   wherein each R′ in the cyclopropyls substituent is, independently,    hydrogen, a substituted hydrocarbyl group, an unsubstituted    hydrocarbyl group, or a halogen.-   E58. The process of Embodiment E56 or Embodiment E57, wherein:-   M is selected from titanium, zirconium, hafnium, vanadium, niobium,    tantalum, chromium, molybdenum and tungsten;-   each X is independently selected from hydrogen, halogen, hydroxy,    substituted or unsubstituted C₁ to C₁₀ alkyl groups, substituted or    unsubstituted C₁ to C₁₀ alkoxy groups, substituted or unsubstituted    C₆ to C₁₄ aryl groups, substituted or unsubstituted C₆ to C₁₄    aryloxy groups, substituted or unsubstituted C₂ to C₁₀ alkenyl    groups, substituted or unsubstituted C₇ to C₄₀ arylalkyl groups,    substituted or unsubstituted C₇ to C₄₀ alkylaryl groups and    substituted or unsubstituted C₇ to C₄₀ arylalkenyl groups; or    optionally are joined together to form a C₄ to C₄₀ alkanediyl group    or a conjugated C₄ to C₄₀ diene ligand which is coordinated to M in    a metallacyclopentene fashion; or optionally represent a conjugated    diene, optionally, substituted with one or more groups independently    selected from hydrocarbyl, trihydrocarbylsilyl, and    trihydrocarbylsilylhydrocarbyl groups, said diene having a total of    up to 40 atoms not counting hydrogen and forming a π complex with M;-   each R², R⁴, R⁸, and R¹⁰ is independently selected from hydrogen,    halogen, substituted or unsubstituted C₁ to C₁₀ alkyl groups,    substituted or unsubstituted C₆ to C₁₄ aryl groups, substituted or    unsubstituted C₂ to C₁₀ alkenyl groups, substituted or unsubstituted    C₇ to C₄₀ arylalkyl groups, substituted or unsubstituted C₇ to C₄₀    alkylaryl groups, substituted or unsubstituted C₈ to C₄₀ arylalkenyl    groups, and —NR′₂, —SR′, —OR′, —SiR′₃, —OSiR′₃, and —PR′₂ radicals    wherein each R′ is independently selected from halogen, substituted    or unsubstituted C₁ to C₁₀ alkyl groups and substituted or    unsubstituted C₆ to C₁₄ aryl groups;-   R³, R⁵, R⁶, R⁷, R⁹, R¹¹, R¹², and R¹³ are each selected from the    group consisting of hydrogen, halogen, hydroxy, substituted or    unsubstituted C₁ to C₁₀ alkyl groups, substituted or unsubstituted    C₁ to C₁₀ alkoxy groups, substituted or unsubstituted C₆ to C₁₄ aryl    groups, substituted or unsubstituted C₆ to C₁₄ aryloxy groups,    substituted or unsubstituted C₂ to C₁₀ alkenyl groups, substituted    or unsubstituted C₇ to C₄₀ arylalkyl groups, substituted or    unsubstituted C₇ to C₄₀ alkylaryl groups and C₇ to C₄₀ substituted    or unsubstituted arylalkenyl groups; and T is selected from:

—B(R¹⁴)—, —Al(R¹⁴)—, —Ge—, —Sn—, —O—, —S—, —SO—, —SO₂—, —N(R¹⁴)—, —CO—,—P(R¹⁴)—, and —P(O)(R¹⁴)—;

-   wherein R¹⁴, R¹⁵, and R¹⁶ are each independently selected from    hydrogen, halogen, C₁ to C₂₀ alkyl groups, C₆ to C₃₀ aryl groups, C₁    to C₂₀ alkoxy groups, C₂ to C₂₀ alkenyl groups, C₇ to C₄₀ arylalkyl    groups, C₈ to C₄₀ arylalkenyl groups and C₇ to C₄₀ alkylaryl groups,    optionally R¹⁴ and R¹⁵, together with the atom(s) connecting them,    form a ring; and M³ is selected from carbon, silicon, germanium, and    tin; or-   T is represented by the formula:

-   wherein R¹⁷, R¹⁸, R¹⁹, R²⁰, R²¹, R²², R²³, and R²⁴ are each    independently selected from hydrogen, halogen, hydroxy, substituted    or unsubstituted C₁ to C₁₀ alkyl groups, substituted or    unsubstituted C₁ to C₁₀ alkoxy groups, substituted or unsubstituted    C₆ to C₁₄ aryl groups, substituted or unsubstituted C₆ to C₁₄    aryloxy groups, substituted or unsubstituted C₂ to C₁₀ alkenyl    groups, substituted or unsubstituted C₇ to C₄₀ alkylaryl groups,    substituted or unsubstituted C₇ to C₄₀ alkylaryl groups and    substituted or unsubstituted C₈ to C₄₀ arylalkenyl groups;    optionally two or more adjacent radicals R¹⁷, R¹⁸, R¹⁹, R²⁰, R²¹,    R²², R²³, and R²⁴, including R²⁰ and R²¹, together with the atoms    connecting them, form one or more rings; and-   M² represents one or more carbon atoms, or a silicon, germanium, or    tin atom.-   E59. The process of any one of Embodiments E31 to E58, wherein the    contacting of the propylene monomer with the first catalyst system    in (a) during time period A1, time period A2, or contacting the    alpha olefin monomer with the second catalyst system in (b) during    time period B, or a combination thereof, is carried out in a liquid    slurry phase.-   E60. The process of any one of Embodiments E31 to E58, wherein the    contacting of the propylene monomer with the first catalyst system    in (a) during time period A1, time period A2, or contacting the    alpha olefin monomer with the second catalyst system in (b) during    time period B, or a combination thereof, is carried out in a gas    phase.-   E61. The process of any one of Embodiments E31 to E58, wherein the    contacting of the propylene monomer with the first catalyst system    in (a) during time period A1, time period A2, or contacting the    alpha olefin monomer with the second catalyst system in (b) during    time period B, or a combination thereof, is carried out in a    solution phase.-   E62. The process of any one of Embodiments E31 to E61, wherein the    polymerization conditions in (a) during time period A1, time period    A2, or in (b) during time period B, or a combination thereof,    comprise a pressure of from about 0.96 MPa to about 7 MPa.-   E63. The process of any one of Embodiments E31 to E62, wherein the    polymerization conditions in (a) during time period A1, time period    A2, or in (b) during time period B, or a combination thereof,    comprise a temperature of from about −20° C. to 150° C.-   E64. The process of any one of Embodiments E31 to E63, wherein time    period A is from 15 to 720 minutes.-   E65. The process of any one of Embodiments E31 to E64, wherein time    period A1 is at least as long as time period A2.-   E66. The process of any one of Embodiments E31 to E65, wherein the    concentration of the hydrogen or other chain transfer agent during    time period A2 is at least three times greater than the    concentration of the hydrogen or other chain transfer agent in time    period A1.-   E67. The process of any one of Embodiments E31 to E66, wherein the    propylene polymer has a multimodal (alternately bimodal) particle    size distribution after time period A1 or after time period A2.-   E68. The process of any one of Embodiments E31 to E67, further    comprising melt processing the propylene polymer at a shear rate of    1000 s⁻¹ or more.-   E69. The process of any one of Embodiments E31 to E68, wherein the    propylene polymer matrix formed in (a) after time period A1 or after    time period A2 has a median PD less than 165 μm, as determined by    mercury intrusion porosimetry (alternately greater than 0.1 μm, or    greater than 1 μm, or greater than 2 μm, or greater than 5 μm, or    greater than 6 μm, or greater than 8 μm, or greater than 10 μm, or    greater than 12 μm, or greater than 15 μm, or greater than 20 μm,    and/or less than 160 μm, or less than 50 μm, or less than 60 μm, or    less than 70 μm, or less than 80 μm, or less than 90 μm, or less    than 100 μm, or less than 120 μm, or less than 125 μm, or less than    140 μm, or less than 150 μm; or from 8 μm up to 150 μm).-   E70. The process of any one of Embodiments E31 to E69, wherein the    propylene polymer matrix formed in (a) after time period A1 or after    time period A2 has a porosity of at least 20% or more (alternately    25% or more, or 30% or more, or 35% or more, or 40% or more; up to    85%, or up to 80%, or up to 75%, or up to 70%, or up to 60%, or up    to 50%).-   E71. The process of any one of Embodiments E31 to E70, wherein the    propylene polymer from (a) after time period A1 or after time period    A2, or the heterophasic copolymer from (b) after time period B, or a    combination thereof, is in a particulated form.-   E72. The process of any one of Embodiments E31 to E70, wherein at    least 90% (alternately at least 95%, or at least 98%, or at least    99%) of the propylene polymer from (a) after time period A1 or after    time period A2, or the heterophasic copolymer from (b) after time    period B, or a combination thereof, by volume has a particle size    greater than about 120 μm (alternately from 150, 200, 300, 400, or    500 μm up to 10, 5, or 1 mm).-   E73. The process of any one of Embodiments E31 to E72, wherein the    propylene polymer from (a) after time period A1 or after time period    A2, or the heterophasic copolymer from (b) after time period B, or a    combination thereof, comprises a multimodal (alternately bimodal)    particle size distribution.-   E74. The process of any one of Embodiments E31 to E73, wherein the    heterophasic copolymer from (b) after time period B comprises an    ethylene copolymer content from about 5 wt % (alternately about 8 wt    %, about 10 wt %, or about 15 wt %, or about 20 wt %, or about 30 wt    %, or about 40 wt %, or about 50 wt %) up to about 25 wt %    (alternately about 30 wt %, about 35 wt %, or about 40 wt %, or    about 50 wt %, or about 60 wt %, or about 70 wt %, or about 75 wt %,    or about 80 wt %, or about 85 wt %) based on the total weight of the    heterophasic copolymer.-   E75. The process of any one of Embodiments E31 to E74, wherein the    heterophasic copolymer from (b) after time period B comprises a    total propylene content of at least 75 wt % (alternately at least 80    wt %, at least 85 wt %, at least 90 wt %, or at least 95 wt %, or at    least 100 wt %) based on the weight of the heterophasic copolymer    composition.-   E76. The process of any one of Embodiments E31 to E75, wherein the    heterophasic copolymer from (b) after time period B comprises a    total comonomer content from about 1 wt % to about 35 wt %    (alternately about 2 wt % to about 30 wt %, or about 3 wt % to about    25 wt %, or about 5 wt % to about 20 wt %) based on the total weight    of the heterophasic copolymer composition.-   E77 The process of any one of Embodiments E31 to E76, wherein the    propylene polymer from (a) after time period A1 or after time period    A2, or the fill phase from (b) after time period B, or a combination    thereof, comprises a CDBI of 50% or more (alternately 60% or more,    70% or more, 80% or more, 90% or more, or 95% or more).-   E78. The process of any one of Embodiments E31 to E77, wherein the    propylene polymer from (a) after time period A1 or after time period    A2, or the fill phase from (b) after time period B, or a combination    thereof, comprises at least 10% isotactic pentads (alternately at    least 20% isotactic pentads, or at least 30% isotactic pentads, or    at least 40% isotactic pentads, or at least 50% isotactic pentads).-   E79. The process of any one of Embodiments E31 to E78, wherein the    propylene polymer from (a) after time period A1 or after time period    A2, or the fill phase from (b) after time period B, or a combination    thereof, comprises more than 5 (alternately more than 10, or more    than 15, or more than 17, or more than 20, or more than 30, or more    than 40) regio defects per 10,000 propylene units, determined by ¹³C    NMR.-   E80. The process of any one of Embodiments E31 to E79, wherein the    propylene polymer from (a) after time period A1 or after time period    A2, or the fill phase from (b) after time period B, or a combination    thereof, comprises less than 200 regio defects (alternatively less    than 175 or less than 150) per 10,000 propylene units.-   E81. The process of any one of Embodiments E31 to E80, wherein the    heterophasic copolymer from (b) after time period B comprises a 1%    Secant flexural modulus of at least 1000 MPa (alternately at least    1300 MPa, or at least 1500 MPa, or at least 1700 MPa, or at least    1800 MPa, or at least 1900 MPa, or at least 2000 MPa, or at least    2100 MPa, or at least 2200 MPa), determined according to ASTM D 790    (A, 1.0 mm/min).-   E82. The process of any one of Embodiments E31 to E81, wherein the    propylene polymer from (a) after time period A comprises a melting    point (Tm, DSC peak second melt) of at least 100° C. or more    (alternately 120° C. or more, or 130° C. or more, or 140° C. or    more, or 150° C. or more, or 160° C. or more).-   E83. The process of any one of Embodiments E31 to E82, wherein the    propylene polymer from (a) after time period A1 or A2 comprises an    Mw/Mn as measured by GPC-DRI of greater than 1 (alternately 1.1, or    1.2, or 1.3, or 1.4) to 20 (alternately 15, or 10, or 5, or 4).-   E84. The process of any one of Embodiments E31 to E83, wherein the    propylene polymer from (a) after time period A comprises a    multimodal (alternately bimodal) molecular weight distribution with    an overall Mw/Mn of greater than 1 to 20 and at least one mode    having an Mw/Mn of greater than 1 to 5.-   E85. The process of any one of Embodiments E31 to E84, wherein the    propylene polymer from (a) after time period A1 or after time period    A2, or the heterophasic copolymer from (b) after time period B, or a    combination thereof, comprises a melt flow rate (MFR, ASTM 1238,    230° C., 2.16 kg) from about 0.1 dg/min (alternately from about 0.2    dg/min, about 0.5 dg/min, about 1 dg/min, about 15 dg/min, about 30    dg/min, or about 45 dg/min) up to about 300 dg/min (alternately    about 75 dg/min, about 100 dg/min, about 200 dg/min, or about 300    dg/min).-   E86. The process of any one of Embodiments E31 to E85, wherein the    propylene polymer from (a) after time period A1 or after time period    A2, or the heterophasic copolymer from (b) after time period B, or a    combination thereof, comprises an Mw (as measured by GPC-DRI) from    50,000 g/mol (alternately 80,000 g/mol, 100,000 g/mol, 200,000    g/mol, 300,000 g/mol, or 330,000 g/mol) to 1,000,000 g/mol    (alternately 800,000 g/mol, 600,000 g/mol, 550,000 g/mol, or 500,000    g/mol).-   E87. The heterophasic copolymer from (b) after time period B, made    by the process according to any one of Embodiments E31 to E86.-   E88. The invention of any one of the preceding embodiments, wherein    the heterophasic copolymer is an impact copolymer.

EXPERIMENTAL

All reactions were carried out under a purified nitrogen atmosphereusing standard glovebox, high vacuum or Schlenk techniques, in a CELSTIRreactor unless otherwise noted. All solvents used were anhydrous,de-oxygenated and purified according to known procedures. All startingmaterials were either purchased from Aldrich and purified prior to useor prepared according to procedures known to those skilled in the art.Silica was obtained from the Asahi Glass Co., Ltd. or AGC ChemicalsAmericas, Inc. (D 150-60 A, D 100-100 A), PQ Corporation (PD 13054), andDavison Chemical Division of W.R. Grace and Company (GRACE 948). MAO wasobtained as a 30 wt % MAO in toluene solution from Albemarle (13.6 wt %Al or 5.04 mmol/g). Deuterated solvents were obtained from CambridgeIsotope Laboratories (Andover, Mass.) and dried over 3 Å molecularsieves. All ¹H NMR data were collected on a Broker AVANCE III 400 MHzspectrometer running Topspin™ 3.0 software at room temperature (RT)using tetrachloroethane-d₂ as a solvent (chemical shift of 5.98 ppm wasused as a reference) for all materials.

Gel Permeation Chromatography-DRI (GPC-DRI): For purposes herein, Mw, Mnand Mw/Mn are determined by using a High temperature gel permeationchromatograph (Polymer Laboratories), equipped with a differentialrefractive index detector (DRI). Three Polymer Laboratories PLgel 10 μmMixed-B columns are used. The nominal flow rate is 1.0 mL/min, and thenominal injection volume is 300 μL. The various transfer lines, columns,and differential refractometer (the DRI detector) are contained in anoven maintained at 160° C. Solvent for the experiment is prepared bydissolving 6 grams of butylated hydroxytoluene as an antioxidant in 4liters of Aldrich reagent grade 1,2,4-trichlorobenzene (TCB). The TCBmixture is then filtered through a 0.1 μm Teflon filter. The TCB is thendegassed with an online degasser before entering the GPC instrument.Polymer solutions are prepared by placing dry polymer in glass vials,adding the desired amount of TCB, then heating the mixture at 160° C.with continuous shaking for about 2 hours. All quantities are measuredgravimetrically. The injection concentration is from 0.5 to 2.0 mg/ml,with lower concentrations being used for higher molecular weightsamples. Prior to running each sample the DRI detector is purged. Flowrate in the apparatus is then increased to 1.0 ml/minute, and the DRI isallowed to stabilize for 8 hours before injecting the first sample. Themolecular weight is determined by combining universal calibrationrelationship with the column calibration which is performed with aseries of monodispersed polystyrene (PS) standards. The Mw is calculatedat each elution volume with following equation.

${\log M}_{X} = {\frac{\log\left( {K_{X}\text{/}K_{PS}} \right)}{a_{X} + 1} + {\frac{a_{PS} + 1}{a_{X} + 1}{\log M}_{PS}}}$where the variables with subscript “X” stand for the test sample whilethose with subscript “PS” stand for PS. In this method, a_(PS)=0.67 andK_(PS)=0.000175 K_(X) are obtained from published literature.Specifically, a/K=0.695/0.000579 for PE and 0.705/0.0002288 for PP.

The concentration, c, at each point in the chromatogram is calculatedfrom the baseline-subtracted DRI signal, I_(DRI), using the equation:c=K_(DRI)I_(DRI)/(dn/dc), where K_(DRI) is a constant determined bycalibrating the DRI, and (dn/dc)=0.109, the refractive index incrementfor both PE and PP. The mass recovery is calculated from the ratio ofthe integrated area of the concentration chromatography over elutionvolume and the injection mass which is equal to the pre-determinedconcentration multiplied by injection loop volume. All molecular weightsare reported in g/mol unless otherwise noted.

Melt Flow Rate (MFR): MFR was measured as per ASTM D1238, condition L,at 230° C. and 2.16 kg load unless otherwise indicated.

Differential Scanning Calorimetry (DSC): Peak crystallizationtemperature (T_(c)), peak melting temperature (T_(m)), heat of fusion(H_(f)) and glass transition temperature (Tg) are measured viadifferential scanning calorimetry (DSC) using a DSCQ200 unit. The sampleis first equilibrated at 25° C. and subsequently heated to 220° C. usinga heating rate of 10° C./min (first heat). The sample is held at 220° C.for 3 min. The sample is subsequently cooled down to −100° C. with aconstant cooling rate of 10° C./min (first cool). The sample isequilibrated at −100° C. before being heated to 220° C. at a constantheating rate of 10° C./min (second heat). The exothermic peak ofcrystallization (first cool) is analyzed using the TA Universal Analysissoftware and the corresponding to 10° C./min cooling rate is determined.The endothermic peak of melting (second heat) is also analyzed using theTA Universal Analysis software and T_(m) corresponding to 10° C./minheating rate is determined. Areas under the DSC curve are used todetermine H_(f), upon melting or H_(c), upon crystallization, and Tg.

Secant Flexural Modulus: The 1% secant flexural modulus (1% SFM) wasmeasured using a ISO 37-Type 3 bar, with a crosshead speed of 1.0 mm/minand a support span of 30.0 mm using an Instron machine according to ASTMD 790 (A, 1.0 mm/min).

Capillary Rheology: All capillary rheology tests on polymers wereconducted with an ARC 2 rheometer at 200° C. using a 1 mm die with apath length of 30 mm. The test conditions were reproduced according toASTM D3835, Standard Test Method for Determination of Properties ofPolymeric Materials by Means of a Capillary Rheometer, and the shearviscosity data were corrected using the Rabinowitsch correction factorto account for the velocity gradient at the die wall for non-Newtonianfluids.

Mercury Porosimetry: Mercury intrusion porosimetry was used to determinethe porosity and the median PD of porous iPPs using an Autopore IV 9500series mercury porosimeter, and unless indicated otherwise, an averageHg contact angle of 130.000°, an Hg surface tension of 485.000 dynes/cm,an evacuation pressure of 50 μm Hg, and an Hg filling pressure of 3.65kPa (0.53 psia) unless otherwise indicated.

Calcination of Raw Silica: Raw silica was calcined in a CARBOLITE ModelVST 12/600 tube furnace using a EUROTHERM 3216P1 temperature controller,according to the following procedure. The controller was programmed withthe desired temperature profile. A quartz tube was filled with 100 gsilica, and a valve was opened and adjusted to flow the nitrogen throughthe tube so that the silica was completely fluidized. The quartz tubewas then placed inside the heating zone of the furnace. The silica washeated slowly to the desired temperature and held at this temperaturefor at least 8 hours to allow complete calcination and removal of wateror moisture. After the dehydration was complete, the quartz tube wascooled to ambient temperature. Calcined silica was recovered in a silicacatcher, and collected into a glass container inside a dry box. Diffusereflectance infrared Fourier transform spectroscopy (DRIFTS) was used asa quality control check. The different silicas used in some of thefollowing examples and their calcination conditions are listed in Table1.

Example 1

Supportation of MAO on Silica: Supported MAO (sMAO) was prepared atreaction initiation temperatures of −20° C. to RT to reduce the risk offragmentation of high SA, small PD silica upon reaction with MAO; or attemperatures up to 100° C. or more, to facilitate higher MAO loadingand/or stronger fixation to minimize MAO leaching from the support. ThesMAO preparation conditions are listed in Table 2 below.

sMAO Method I: For low temperature sMAO preparation to minimize sMAOfragmentation (sMAO2, sMAO7), the following or a similar procedure wasused. The silica was slurried in a reactor with 10× toluene—nota bene,all slurry and solvent liquid ratios are given as weight ratios relativeto the starting silica material, e.g., raw silica or silica supportedMAO and/or catalyst. The reactor was chilled in a freezer to −20° C.and/or maintained at RT. The reactor was stirred at 500 rpm. Cold (−20°C.) 30 wt % MAO was added slowly to the reactor to maintain thetemperature below 40° C., and then the reactor was stirred at 350 rpm atRT for 3 hours. The mixture was filtered through a medium frit, the wetsolid washed with 10× toluene and then 10× hexane, and dried undervacuum for 3 hours.

sMAO Method II: For partial fragmentation of sMAO (sMAO3) andpreparation of comparative, non-fragmented sMAO (CsMAO1, CsMAO4), thefollowing or a similar procedure was used. The silica was slurried in4-5× toluene, chilled to −20° C., and 30 wt % MAO in toluene was addedin two equal aliquots. The first aliquot was added under agitation, andthe resultant slurry chilled in the freezer for about 5 minutes beforeaddition of the second aliquot to maintain temperature below RT. Theslurry was then allowed to stir for 2 hours at RT, filtered, reslurriedin 3× toluene for 15 min and filtered a second time. Then the materialwas reslurried a second time in 3× toluene, stirred for 30 min at 80°C., filtered, reslurried a third time in 3× toluene, stirred at 80° C.for 30 min, filtered, rinsed with 3× toluene, rinsed with 3× pentane,and dried under vacuum overnight.

sMAO Method III: For high temperature sMAO preparation (fragmentedsMAO1;

non-fragmented sMAO4, sMAO5, sMAO6, sMAO8; comparative CsMAO2), thefollowing or a similar procedure was used. The silica was slurried into6× toluene in a reactor stirred at 500 rpm. The 30 wt % MAO solution wasadded slowly to the reactor to maintain the temperature below 40° C.,then the reactor was stirred at 350 rpm at RT for 30 mins, and thenheated at 100° C. for 3 hours. The mixture was filtered through a mediumfrit, the wet solid was washed with 10× toluene, then 10× hexane, anddried under vacuum for 3 hours.

CsMAO Method IV: For comparative CsMAO5, the following or a similarprocedure was used. The silica was slurried into 6× toluene in a stirredreactor and chilled in the freezer. The 30 wt % MAO solution was addedin 3 parts with the silica slurry returned to the freezer for a fewminutes between additions. The slurry was stirred at RT for 2 hours,filtered, reslurried in 4× of toluene for 15 min at RT, and thenfiltered again. The solid was reslurried in 4× toluene at 80° C. for 30min and then filtered. The solid was reslurried in 4× toluene at 80° C.for 30 min and then filtered a final time. The solid was washed with 2×toluene, then with pentane and dried under vacuum for 24 hours.

Example 2

Catalyst Supportation. The metallocene catalyst precursor compounds(MCN) and Ziegler-Natty catalysts (ZN) used in the examples andcomparative examples below are identified in Table 3. The catalystpreparation/supportation conditions and yield of supported catalystexamples SC1-SC10 according to the present invention, and comparativeexamples CSC1 and CSC2, are given in Table 4.

Finished Catalyst Method I (SCat1-SCat8, SCat10; Comparative CSC1): Areactor was charged at RT with solid sMAO and 5× toluene. The slurry wasstirred at 350 rpm. TIBA (neat) was added at 0.34 mmol/g sMAO slowlyinto the sMAO slurry and the reactor stirred for 15 mins. Then, the MCNwas added and the solution mixture was stirred for 1 to 2 hours at RT.The slurry was filtered through a medium frit. The wet solid was washedtwice with 10× toluene, once with 10× hexane, and dried under vacuum for3 hours, yielding free flowing solid supported catalysts (SCat or CSC).

Finished Catalyst Method II (SCat9, SCat11): MCN was preactivated bymixing with 40 eq. of MAO, and stirring for 1 hour at RT. Meanwhile, thesMAO was slurried in 20 mL of toluene and chilled in a freezer for 1min. The preactivated MCN solution was then added to the chilled sMAOslurry, and the resulting mixture was allowed to stir for 1 hour, withcooling in the freezer for 1 minute out of every 10 minutes. Theresulting slurry was heated to 40° C. for 2 hours and filtered,reslurried in 20 mL toluene at 60° C. over a period of 5 mins, stirredfor 30 mins, and filtered again. The toluene wash was repeated twice,the solid material washed with 50 mL pentane, and dried under vacuumovernight to obtain a pink/purple solid.

Example 3

Preparation of Porous iPP (“First Stage Reactor” or “Stage 1A and or1B”). Porous iPP was prepared according to embodiments of the presentinvention (PiPP1-PiPP11) and according to comparatives (CiPP1-CiPP5)with the following representative procedure or similar. A 35 mL catalysttube was loaded with 2 mL of 0.091M TNOAL (AkzoNobel) in hexane andinjected into the reactor with nitrogen. The catalyst tube was thenpressurized with hydrogen, which was then added to the reactor. Next,600 mL of propylene was added to the reactor through the catalyst tube.The reactor was heated to 70° C. with a stir rate of 500 rpm. Then, thesupported or comparative catalyst was loaded into a second catalyst tubeas a dry powder and inserted into the reactor along with 200 mL ofpropylene. The reactor was maintained at 70° C. for 1 hour. Finally, thereactor was vented and polymer collected. The iPP polymerization dataare shown in Table 5, mercury intrusion porosimetry data in Table 6A,and capillary rheology data and polymer characterizations in Table 6B.

Representative plots of incremental intrusion (mL/g) vs pore sizediameter (μm) are shown graphically in FIGS. 4, 5, and 6 for inventivesample PiPP4 and comparative samples CiPP2 and CiPP3. Statistically, thelarge pores indicated at the left sides of these incremental intrusionplots represent interstitial spaces between particles, and are accountedfor in the reporting of the intrusion data. From FIG. 4, it is seen thatthe inventive PiPP4 has a relatively large number of pores in the 6-100μm range, and a median pore diameter of 12.2 μm as reported in Table 6A.The inventive samples PiPP1, PiPP2, PiPP3, and PiPP4 have a porositygreater than 30% or greater than 40%, and the median pore diameters arein a suitable range, e.g., 10-100 μm that will facilitate a relativelyhigh rubber loading relative to iPP prepared using an MCN catalystsupported on a conventional silica support.

From FIG. 5, it is seen that the comparative CiPP2 prepared with themetallocene supported on 948 silica has relatively few pores less than100 μm, and a median pore diameter of 165 μm is reported in Table 4. Themedian pore diameter is greater than 160 μm, which has been found to betoo high to facilitate high rubber loading. On the other hand, in FIG. 6it is seen that the comparative CiPP3 prepared with ZN has a muchdifferent morphology at the other end of the spectrum with a highproportion of pores less than 6 μm range, and a median pore diameter of5 μm is reported in Table 4.

As seen from the capillary rheology data presented in Table 6B, similarviscosities at the high shear rates probed by capillary rheology confirmsimilar processability at conditions similar to commercial processingequipment, i.e., shear rates of 1000 sec⁻¹ or higher. Thus, capillaryrheology confirms the MCN performance benefits of the inventive porousiPP, prepared with the inventive supports, on existing commercialprocessing equipment.

These examples demonstrate that the inventive iPP can be prepared usinga silica-supported MCN catalyst, thus providing a narrower molecularweight distribution, narrower composition distribution in the case ofcopolymers, lower extractables, processability and other advantages ofan iPP prepared with a single site catalyst such as MCN, as compared toa similar iPP prepared using a ZN catalyst system.

Example 4

ICP Polymerization from Unimodal and Bimodal iPP. In this example, aunimodal or bimodal iPP prepolymer was prepared, then followed byaddition of a comonomer to prepare an ICP heterophasic copolymer.Polymerization data for runs of the bimodal prepolymer, and ICP based onunimodal and bimodal iPP, are presented in Table 7.

For Bimodal iPP (Runs 1, 2, 5): the following procedure was used exceptRun 1 was stopped after making the iPP, and the polymerization times inRuns 2 and 5 were as indicated in Table 7. To make the iPP prepolymer,in a dry box, sCat2 slurry containing the catalyst amount indicated inTable 7 was charged to a catalyst tube, followed by 1 mL hexane (N₂sparged and mol sieve purified). To a 3 mL syringe was charged to acatalyst tube, 1.0 ml of a solution of 5 ml TNOAL in 100 ml hexane. Thecatalyst tube and the 3 ml syringe were removed from the dry box and thecatalyst tube attached to a 2 L reactor while the reactor was beingpurged with nitrogen. The TNOAL was injected into the reactor via thescavenger port capped with a rubber septum, and the scavenger port valvewas then closed. Propylene (1000 ml) was introduced to the reactorthrough a purified propylene line. The agitator was brought to 500 rpm.The mixture was allowed to mix for 5 minutes at RT. The catalyst slurryin the catalyst tube was then flushed into the reactor with 250 mlpropylene. The polymerization reaction was allowed to run for 5 minutesat RT.

For the Stage A1 iPP Prepolymer: the reactor temperature was increasedto and maintained at 70° C. for the indicated time period. For stage A2iPP, at the end of the A1 stage, a 150 mL bomb with 0.207 MPa (30 psig)H₂ was opened to the reactor. A 0.220 MPa (31.9 psi) increase in reactorpressure and a 3° C. increase in reactor temperature were observed. Thereaction was allowed to run for the indicated time after the H₂ charge.

For Stage B ICP: the agitator was set to 250 rpm 1 minute before the endof time period A2. At the end of the A2 period, using the reactor ventblock valve, the reactor pressure was vented to 1.475 MPa (214 psig)while maintaining reactor temperature as close as possible to 70° C. Theagitator was increased back up to 500 rpm. The reactor temperature wasstabilized at 70° C. with the reactor pressure reading 1.481 MPa (214.8psig). Ethylene gas at 0.938 MPa (136 psi) was introduced into thereactor, targeting a total pressure of 2.41 MPa (350 psig). The reactorwas held at this pressure for 20 minutes. Using the reactor vent blockvalve, the reactor was quickly vented to stop the polymerization. Thereactor bottom was dropped and a polymer sample collected. Afterovernight drying, the sample was a free flowing ICP resin.

ICP from Unimodal iPP (Runs 3-4, 6-8): iPP prepolymer was preparedgenerally as described above. After heating the reactor to 70° C., a 150mL bomb filled with H₂ pressure as indicated in Table 7 was opened tothe reactor. The reaction was allowed to run for A1 time indicated afterthe H₂ charge. At 1 minute before the A1 time, the agitator was set to250 rpm. At the end of the A1 time, using the reactor vent block valve,the reactor pressure was vented to 1.475 MPa (214 psi) while maintainingreactor temperature as close as possible to 70° C. The agitator wasincreased back up to 500 rpm. The reactor temperature was stabilized at70° C. with the reactor pressure reading 1.481 MPa (214.8 psi). Ethylenegas at 0.938 MPa (136 psig) was introduced to the reactor, targeting atotal pressure of 2.413 MPa (350 psi). The reactor was held at thispressure for the B (ICP) stage time indicated. Using the vent blockvalve, the reactor was quickly vented to stop the polymerization.Dropped reactor bottom and collected sample. Using the reactor ventblock valve, the reactor was quickly vented to stop the polymerization.The reactor bottom was dropped and a polymer sample collected. Afterovernight drying, the sample was a free flowing ICP resin.

Example 6

iPP from Controlled Fragmentation of Catalyst Support. In this example,MCN compounds were supported on sMAO prepared at varying temperatureconditions and metal alkyl treatments to investigate catalyst activityand the PSD, stiffness, and other properties of the iPP and ICP madewith the catalyst systems. The catalyst systems CSC3, SCat2, SCat11, andSCat1A were used to prepare comparative and inventive porous iPPpolymers CiPP6, PiPP12, PiPP13, and PiPP13, respectively, using thepolymerization procedures of Example 3 at the polymerization conditionslisted in Table 8 below.

As shown in FIG. 7, the median size of the CiPP6 particles producedusing the conventionally supported MCN system has a bell-shaped unimodalPSD centered near 700 μm.

As shown in FIG. 8, PiPP12, produced using a generally non-fragmentedsupport that survived generally intact from MAO supportation conductedat ambient or below for 3 hours, produced relatively large iPP particleswith very few, if any, particles less than 500 μm, and most or allgreater than about 600 μm up to 1500 μm or more.

As shown in FIG. 9, PiPP13, produced using a partially fragmentedsupport from an MAO supportation reaction conducted at 80° C. for 1hour, produced a bimodal PSD comprising a small particle mode centerednear 200 μm and the larger particles having a size increasing from near600 μm up to 1000 μm or more.

As shown in FIG. 10, PiPP14, produced using a fragmented support from anMAO supportation reaction conducted at 100° C. for 3 hours, produced aPSD comprised mainly (>80 wt %) of small particles centered near 200 μm,with only small amounts (<10 wt %) of larger particles in the 500 μm to1000 μm range.

Example 7

iPP from Catalyst Supportation with and without TIBA Treatment. In thisexample, MAO was supported on D 150-60 A silica using both hightemperatures (100° C. for 3 hours, for high loading (11.5 mmol Al/gsilica) to gain iPP polymerization activity) and low temperatures (<30°C. for 3 hours, for low loading (7 mmol Al/g silica) to build highporosity iPP resins), with and without TIBA treatment to investigate anyactivity enhancement. The MAO and MCN supportation procedures followbelow, and the catalyst systems were used to prepare iPP and ICP usingprocedures similar to Examples 3-4.

High Temperature Supportation with TIBA Treatment (iPP15): A reactor wascharged with 10 g of silica S1 and 5× toluene. While stirring at 350rpm, 22.8 g of 30% MAO (11.5 mmol Al/g silica) were slowly added to thesilica slurry over 15 min, which was then allowed to stir at RT for 30min and then heated in an oil bath to 100° C. over about 35 min. Thetemperature of the slurry was maintained at 100° C. for 3 hours whilestirring. The oil bath was then removed and the reactor allowed to coolto 50° C. under ambient conditions. The slurry was then filtered througha fine frit and the filtrate sampled for NMR analysis, which indicatedneither MAO nor TMA was present. The wet solid was washed with 4× hexaneand dried under vacuum for 90 mins, yielding 18.0 g sMAO, which wasanalyzed and found to still contain about 7% solvent. Testing of the11.5 mmol Al/g silica sMAO (“sMAO-11.5”) indicated uptake of anadditional 5.07 mmol Al/g silica. Then, 3.1 g of the sMAO-11.5 wereslurried into 8 g toluene in a 20 mL vial. About 0.17 g neat TIBA (0.85mmol) were added slowly to the slurry with vigorous shaking. The slurrywas then placed on a shaker for 10 min during which gas evolution wasobserved, indicating that the sMAO had undergone fragmentation whilebeing heated at 100° C. for 3 hr, uncovering reserved surface area andallowing more reactive hydroxyls to be exposed for reaction. Then, 30 mgMCN3 (0.051 mmol Zr) was added to the slurry and the mixture was shakenon a shaker for 2 hours at RT. The dark brown slurry was filtered,washed with 10 g toluene and 2×6 g hexane, and then dried under vacuumfor 2 hours, yielding 3.08 g sCat+TIBA. This sCat was used to prepareiPP15 as indicated in Table 9.

High Temperature Supportation without TIBA Treatment (iPP16): To areactor were charged 11.0 g of sMAO-11.5 and 53 g toluene, and stirredat 350 rpm. A 20 mL vial was charged simultaneously with 0.130 g of MCN3(0.22 mmol Zr) and 6.11 g MAO for an additional 5 mmol Al/g silicacharge, based on the above sMAO uptake analysis. The mixture in the vialwas shaken well before it was added to the slurry in the reactor. Themixture was then allowed to stir at RT for 2 hours, then filteredthrough a fine frit, washed twice with 5× toluene and twice with 4×hexane, and dried under vacuum for 60 hours at RT, yielding 11.3 g sCat.This sCat was used to prepare iPP16 as indicated in Table 9.

Low Temperature Supportation with TIBA Treatment (ICP1): In a glove box,5.0 g silica S2 and 10× toluene were added to the reactor and placed ina freezer at −20° C. for 30 min. Then, 7.0 g of prechilled 30% MAO (7.0mmol Al/g silica) were slowly added to the silica slurry stirred at 600rpm over 20 min. The stirring rate was reduced to 300 rpm and thereactor held for 3 hours at RT. The stirrer was stopped and the slurryallowed to settle for 5 min prior to being filtered through a coarsefrit. The wet cake was washed twice with 10× toluene. The wet cake wascharged into a reactor with 7× toluene and stirred at 300 rpm. Then,0.501 g TIBA were added to the slurry, and after stirring for 15 min,0.139 g of MCN3 was added to the reactor. After stirring 1 hr at RT, theslurry was filtered through a coarse frit and washed twice with 8×toluene and twice with 8× hexane. The wet cake was dried under vacuumfor 1 hr, yielding 7.04 g. This sCat was used to prepare ICP1 asindicated in Table 9.

Low Temperature Supportation without TIBA Treatment (ICP1): a similarprocedure was used but without TIBA addition, and the yield was 7.07 g.This sCat was used to prepare ICP2 as indicated in Table 9.

As indicated in Table 9, TIBA treatment increased the catalyst activity,considered to be attributable to the removal of possible hydroxyl groupswhich may have been uncovered during MAO supportation and/or supportfragmentation. The polymer characterization and stiffness data arepresented in Table 10. These data further confirm that the catalystsaccording to embodiments disclosed herein provide a significantimprovement in the iPP and/or ICP stiffness characterized by 1% secantflex modulus stiffness, e.g., greater than about 1950 MPa, greater thanabout 2000 MPa, greater than about 2100 MPa, greater than about 2200MPa.

FIG. 11 is a GPC-4D chromatogram for ICP1 indicating the ethylene uptakeis about 18-20 wt % and the EP rubber uptake is 37 wt %. Calculated fromthe yield data, the total EP rubber uptake is 44 wt %. Accordingly,37-44 wt % EP rubber uptake may be achieved according to embodiments ofthe present invention, representing a vast improvement over impactcopolymers produced using ZN catalyst systems known in the art, whichtypically require post reactor addition of plastomer to produce the ICP.

All documents described herein are incorporated by reference herein forpurposes of all jurisdictions where such practice is allowed, includingany priority documents, related application and/or testing procedures tothe extent they are not inconsistent with this text. As is apparent fromthe foregoing general description and the specific embodiments, whileforms of the invention have been illustrated and described, variousmodifications can be made without departing from the spirit and scope ofthe invention. Accordingly, it is not intended that the invention belimited thereby. Likewise, the term “comprising” is consideredsynonymous with the term “including.” Likewise whenever a composition,an element or a group of elements is preceded with the transitionalphrase “comprising”, it is understood that we also contemplate the samecomposition or group of elements with transitional phrases “consistingessentially of”, “consisting of”, “selected from the group of consistingof”, or “is” preceding the recitation of the composition, element, orelements and vice versa.

TABLE 1 Silica Properties and Calcination Temperature Tc PS SA PV PD (nmSupport SiO₂ (° C.) (um) (m²/g) (mL/g) (Å)) S1 D 150-60A 200 150 7331.17  6.4 (64) S2 D 150-60A 600 150 733 1.17  6.4 (64) S3 D 100-100A 200100 543 1.51 11.1 (111) S4 D 100-100A 600 100 543 1.51 11.1 (111) S5 PD13054 200 130 671 1.11  6.6 (66) S6 PD 13054 600 130 671 1.11  6.6 (66)S7 PD 14024 200  85 611 1.40  9.2 (92) CS1 948 130  58 278 1.68 24.2(242) CS2 948 600  58 278 1.68 24.2 (242) CS3 MS 3050 600  90 500 3.0  24 (240) Tc—Calcination temperature; PS—average particle size (frommanufacturer); SA—BET surface area (from manufacturer); PV—pore volume(from manufacturer); PD—pore diameter (from manufacturer)

TABLE 2 Supported MAO Preparation Conditions Silica MAO^(a) T2 SilicaMass (mmol T1^(b) T2^(c) Time^(d) Yield sMAO# # (g) Al/g) (° C.) (° C.)(hr) (g) sMAO1 S1 10.15 11.5 RT 100 3 17.02 sMAO2 S2 10.67 7.0 <RT RT 314.23 sMAO3 S2 16.2 12.3 <RT 80 1 27.1 sMAO4 S3 5.01 12.5 RT 100 3 8.72sMAO5 S4 5.06 10.0 RT 100 3 8.46 sMAO6 S5 5.02 11.5 RT 100 3 8.73 sMAO7S6 5.01 7.0 RT RT 3 7.20 sMAO8 S7 1.00 13.0 RT 100 3 1.68 CsMAO1 CS16.31 12.3 <RT 80 1 10.4* CsMAO2 CS2 5.00 9.5 RT 100 3 7.07 CsMAO3 CS25.00 8.63 <RT 80 1 6.6* CsMAO4 CS3 5.00 12 <RT 80 1 8.5* CsMAO5 CS120.86 12.2 <RT RT 2 28.94 ^(a)MAO proportions given in total mmol Al/gsilica; ^(b)MAO addition temperature T1; ^(c)MAO reaction temperature T2after MAO addition; ^(d)Time for MAO under reaction temperature T2.*estimated based on MAO charge by assuming MAO molecular weight onsupport = 59 g/mol.

TABLE 3 Catalysts Catalyst Catalyst precursor compound MCN1[(6-methyl-8-phenyl-1,2,3-hydroindacenyl)(7-(4-tert-butylphenyl)-2-isopropyl indenyl) dimethylsilyl]zirconiumdichloride MCN2 rac-dimethylsilyl bis(2-cyclopropyl-4-(3′,5′-di-tert-butylphenyl)-indenyl) zirconium dichloride MCN3 rac-dimethylsilylbis(2-methyl-4-phenyl-indenyl) zirconium dimethyl MCN4 rac-dimethylsilylbis(2-methyl-4-(3′,5′-di- tert-butyl-4′-methoxy-phenyl)- indenyl)zirconium dichloride MCN5 rac-dimethylsilyl[(4-(4′-tert-butylphenyl)-2-isopropylindenyl)(4-(4′-tert-butylphenyl)- 2-methylindenyl)] zirconiumdimethyl MCN6 rac-dimethylsilyl(4-o-biphenyl-2-(1-methylcyclohexyl)methyl-indenyl)(4- (3′,5′-di-tert-butylphenyl)-2-methyl-indenyl)zirconium dichloride MCN7 rac-dimethylsilylbis(2-cyclopropyl-4- (3′,5′-di-tert-butylphenyl)-indenyl) hafniumdichloride MCN8 rac-pentamethylenesilylene-bis(2,4,7-trimethylindenyl)hafnium(IV) dimethyl ZN1 Commercial Ziegler-Nattapolypropylene catalyst from Toho Titanium

TABLE 4 Supported Catalyst Preparation Conditions sMAO MCN Calc.Reaction Wt Wt Pre- Zr^(b) TIBA Reaction Time Yield SCat# sMAO# Cat. (g)(g) Activation ^(a) (Wt %) (g) Temp^(c) (h) (g) SCat1 sMAO1 MCN4 1.00.0205 No 0.12 0.072 18-25° C. 1 0.98 SCat1A sMAO1 MCN2 1.0 0.046 No0.30 0.072 18-25° C. 1 1.0 SCat2 sMAO2 MCN2 15.0 0.278 No 0.12 1.0218-25° C. 1 14.2 SCat2A sMAO2 MCN1 1.00 0.017 No 0.20 0.078 18-25° C. 10.88 SCat2B sMAO2 MCN4 8.46 0.064 No 0.08 0.584 18-25° C. 1 8.30 SCat3sMAO4 MCN2 1.01 0.021 No 0.12 0.079 18-25° C. 1 1.00 SCat4 sMAO5 MCN48.05 0.064 No 0.08 0.584 18-25° C. 1 8.46 SCat5 sMAO6 MCN2 3.1 0.061 No0.12 0.18 18-25° C. 2 3.55 SCat6 sMAO7 MCN2 1.00 0.017 No 0.12 0.07918-25° C. 1 0.86 SCat7 sMAO8 MCN2 1.68 0.033 No 0.12 0.121 18-25° C. 11.77 SCat8 sMAO8 MCN4 1.00 0.0082 No 0.08 0.073 18-25° C. 2 0.96 SCat9sMAO3 MCN1 0.6253 0.0178 Yes 0.34 0 18-25° C. 1 0.4967 SCat10 sMAO2 MCN2464.1 12.8 No 0.18 45.56 18-25° C. 3 616.5 SCat11 sMAO3 MCN2 1.0 0.03Yes 0.30 0 18-25° C. 1 1.00^(d) CSC1 CsMAO1 MCN4 1.01 0.0297 No 0.300.078 18-25° C. 1 1.00^(d) CSC2 CsMAO2 MCN5 10.5 0.1824 Yes 0.21 0 <RT 18.04 CSC3 CsMAO3 MCN4 1.05 0.043 Yes 0.21 0 18-25° C. 1 1.00^(d) CSC4CsMAO2 MCN3 1.0012 0.0305 Yes 0.32 0 <RT 1 0.942 CSC5 CsMAO5 MCN2 0.85650.031 Yes ND 0 <RT 1 0.8066 CSC6 CsMAO5 MCN4 ND ND Yes ND 0 <RT 1 ^(a)Pre-activation: MCN is mixed with 40 eq. MAO (40:1 Al:Zr) at RT for 1 hrbefore adding to sMAO slurry; ^(b)Calculated based on charge materials;^(c)<RT = chilled in the freezer inside the dry box, −20 to −35° C., andwarming up at RT after taking out from the dry box for reagent addition.^(d)estimated based on charges; ND—data not determined or otherwise notavailable.

TABLE 5 Porous Isotactic Polypropylene Polymerization 1^(st) Stage2^(nd) Stage H₂ P H₂ P iPP Activity iPP (kPa Time (kPa Time Yield (gP/giPP Porosity^(e) iPP PV^(f) 1% SFM iPP Mw iPP PiPP# Cat.^(a) Mod^(b)(psi)) (min) (psi)) (min) (g) cat-h) MFR^(d) (%) (mL/g) (MPa) (kg/mol)PDI PiPP1 SCat9 U 27.6 (4) 50 NA NA 49.4 1097 ND 36.37 0.613 1676 1352.46 PiPP2 SCat9 U  414 (60) 32 NA NA 40.5 2132 ND 41.2 0.758 1427 ND NDPiPP3 SCat2A U  0 50 NA NA 107.1 1285 0.96 33.37 0.515 1517 478 2.70PiPP4 SCat2 U  0 40 NA NA 57.9 869 4 32.25 0.510 1169 ND ND PiPP5 SCat2B  0 50 30 10 232.7 1164 219.3 32.08 0.511 1503 ND ND PiPP6 SCat11 B  010 30 45 69.8 1730 82.6 32.96 0.571 1919 226 10.57 PiPP7 SCat11 B  0 1035 45 93.4 2317 145.3 35.18 0.583 1646 201 9.05 PiPP8 SCat2 B  0 50 3010 127.5 1275 118 ND ND 1618 198.9 14.9 PiPP9 SCat2B U 15 40 NA NA 85.22557 39.0 ND ND 1139 203.5 4.33 PiPP10 SCat2 U^(g)  207 (30)^(g) 60^(g)NA NA 127 1290 118 ND ND 1618 198.9 14.9 PiPP11 SCat4 U  103 (15) 40 NANA 85.2 2540 39 ND ND 1139 203.5 4.33 CiPP1 CSC2 U  0 40 NA NA 41.8 41502.5 28.42 0.414 ND ND ND CiPP2 SCat11 U 48.3 (7) 50 NA NA 169 2820 42.126.05 0.378 ND ND ND CiPP3 ZN1 U  172 (25) 50 NA NA 136 2360 ND 27.990.413 1453 ND 6.49 CiPP4 CSC5 U^(g)  345 (50)^(g) 55^(g) NA NA 74.1 1220102 ND ND 2143 234.9 15.3 CiPP5 CSC6 U  138 (20) 60 NA NA 54.2 3040 52ND ND 1148 181.5 2.63 ^(a)catalyst, see Table 4; ^(b)iPP modality, B =bimodal, U = unimodal; ^(c)activity given as grams polymer per gram ofcatalyst per hour; ^(d)melt flow rate, ASTM D1238, condition L, at 230°C. and 2.16 kg load; ^(e)porosity per Hg porosimetry; ^(f)pore volumeper Hg porosimetry; 1% SFM-1% secant flex modulus; ^(g)H2 was addedafter 10 min prepolymerization (5 min at RT +/−5° C., 5 min heatingincluded in times given), high Mw mode presumed negligible; A—notapplicable; ND—not determined or otherwise not available.

TABLE 6A Porosimetry Data for Inventive and Comparative Porous iPPHomopolymers PiPP# PiPP3 PiPP4* PiPP5 PiPP6 PiPP7 CiPP2 CiPP3Catalyst/Support SCat2A/S2 CAT2/S1 SCat2/S2 SCat2/S2 SCat12/S2 CAT2/CS1ZN1 Total intrusion (mL/g) 0.515 0.511 0.511 0.571 0.583 0.378 0.431Total pore area (m²/g) 44.4 40.4 43.6 42.9 42.4 38.5 37.5 Median PD (μm)84.2 12.2 84.6 22.7 25.1 165 5.00 Bulk density @ 3.65 kPa (g/mL) 0.6480.632 0.628 0.577 0.604 0.688 0.677 Apparent (skeletal) density (g/mL)0.972 0.932 0.924 0.861 0.931 0.931 0.941 Porosity (%) 33.4 32.3 32.133.0 35.2 26.0 28.0 Stem Volume Used (%) 63 60 29 32 32 66 40 *Hgfilling pressure 3.52 kPa (0.51 psia)

TABLE 6B Capillary Rheometry Data for Inventive and Comparative PorousIPP Homopolymers Catalyst/ SV** (Pa-s) 1% SFM Mw Mn iPP# Support MFR* @1 sec⁻¹ @ 1000 s⁻¹ @ 2000 s⁻¹ (MPa) (kg/mol) (kg/mol) PDI CiPP4 CSC5 1022650 23.2 16 2143 234.9 15.37 15.3 PiPP10 SCat2 118 2090 107 20 1618198.9 13.36 14.9 CiPP5 CSC6 52 2476 71.7 45 1148 181.5 68.81 2.63 PiPP11SCat4 39 3470 75.6 46 1139 203.5 46.97 4.33 *MFR—Melt Flow Rate, ASTMD1238, condition L, at 230° C. and 2.16 kg load; **SV—Shear Viscosity(apparent viscosity)

TABLE 7 iPP/ICP Polymerization Data iPP^(1/2) Stage 2 ICP Run iPP/ iPPiPP^(1/2) H₂ Time Time Cat Yield Activity Cv^(d) # Cat ICP Modality(PSI) (min) (min) (g) (g) (g P/g cat/hr) (wt%) 1 SCat2 iPP Bi 0/30 50/10N/A 0.10 144 1440 NA 2 SCat2 ICP Bi 0/30 50/10 20 0.10 254 1904 35 3SCat2 ICP Uni 0/NA 60/NA 10 0.10 186 1596 39 4 SCatl ICP Uni 5/NA 10/NA40 0.017  60.8 4294 76 5 SCat3 ICP Bi 0/30 10/15 20 0.020  66.8 4450 346 SCat4 ICP Uni 0/NA 30/NA 10 0.20 118.5  889^(a) 43^(b) 7 SCat7 ICP Uni0/NA 40/NA 20 0.050  57.0 1140 38 8 C5C1 ICP Uni 0/NA 40/NA 20 0.10 2712710 34^(c) iPP^(1/2) H₂ is the iPP Stages I and II H₂ pressure in the150 mL bomb charged into the reactor; iPP^(1/2) T is the iPP StagesA1/A2 polymerization times; ICP Time is the Stage B time; ^(a)too muchcatalyst charge caused melted polymer that likely decreased theactivity; ^(b)some melted ICP resins formed, the Cv is for thenon-melted majority ICP resins; ^(c)comparative example; serious reactorfouling was found; ^(d)from RT recrystallization of iPP from ICP xylenesolution obtained from 130° C. 60 min heating, the actual Cv istypically 10-20 wt % higher.

TABLE 8 iPP Polymerization Based on Varying MCN SupportationTemperatures to Control iPP Particle Size Distribution Supp. T MAO Cat.Stage 1 Stage 1 Stage 2 Stage 2 (° C.)/ (mmol/g Wt Rxn T H₂ Time H₂ TimeiPP# Cat. time (h) SiO₂) (g) (° C.) (kPa) (min) (kPa) (min) iPP PSDCiPP6 CSC3 80/1  8.63 0.020 70 0 60 0 0 Uni, 700 μm PiPP12 SCat2<30/3    7.00 0.10 70 0 50 30 10 80% 600+ μm PiPP13 SCat11 80/1  120.040 70 0 50 30 10 200 μm/1000 μm PiPP14 SCat1A 100/3  11.5 0.046 70 050 30 10 80% 200 μm

TABLE 9 iPP Polymerization Data TIBA Treatment Comparisons CATALYSTiPP-Stage A EPR MAO Stage A1 Stage A2 Stage B iPP#/ (mmol/g TIBA sCatCat Activity T H₂ t H₂ t H₂ t ICP# sCat SiO₂) Y/N (mg) (g P/g cat-h) (°C.) (kPa) (min) (kPa) (min) (kPa) (min) PiPP15 S1/MCN3 11.5 Yes 12.62962 70 0 50 103.4 5 NA NA PiPP16 S1/MCN3 11.5 No 12.9 1288 70 0 50103.4 5 NA NA ICP1 S2/MCN2 7.0 Yes 100 2527 70 0 50 206.8 20 0 20 ICP2S2/MCN2 7.0 No 110 672 70 0 50 206.8 20 0 20

TABLE 10 Stiffness of iPP/ICP Resins iPP#/ Tm 1% SFM Mw Mn ICP# (° C.)MFR (MPa) (g/mol) (g/mol) PDI PiPP15 150.7 0.23 2092 641227 108035 5.94PiPP16 150.2 0.09 2163 784949 73476 10.68 ICP1 151.2 0.38 1978 663795159275 2.47 ICP2 150.7 0.11 2213 693051 193182 3.59

What is claimed is:
 1. A process for polymerization of propylene and acomonomer, comprising: (a) contacting propylene monomer underpolymerization conditions with a first catalyst system, comprising asingle site catalyst precursor compound, an activator, and a supporthaving an average particle size of more than 30 microns, a surface areaof 400 m²/g or more, a pore volume of from 0.5 to 2 mL/g, and a meanpore diameter of from 1 to 20 nm (10 to 200 angstroms) as determined byBET nitrogen adsorption, to form a matrix phase of propylene polymercomprising at least 50 mol% propylene and having a porosity of 15% ormore as determined by mercury intrusion porosimetry; and (b) contactingan alpha olefin monomer selected from ethylene, C₃ to C₂₀ alpha olefins,or a combination thereof, including at least one alpha olefin other thanpropylene, with a second catalyst system under polymerization conditionsto form a fill phase for the pores of the matrix, wherein the secondcatalyst system comprises a metallocene catalyst precursor compound, anactivator, and a support, and wherein the second catalyst systemcomprises, compositionally, the same or different single site catalystprecursor compound as in the first catalyst system, the same ordifferent activator as in the first catalyst system, the same ordifferent support as in the first catalyst system, or any combinationthereof, (c) obtaining a heterophasic propylene copolymer compositioncomprising: A) a matrix phase comprising at least 50 mol % propylene andhaving: 1) a 1% Secant flexural modulus of at least 1000 MPa, determinedaccording to ASTM D 790 (A, 1.0 mm/min); 2)more than 5 and less than 200regio defects (defined as the sum of 2,1-erythro and 2,1-threoinsertions, and 3,1-isomerizations) per 10,000 propylene units,determined by ¹³C NMR; and 3) when comonomer is present, a compositiondistribution breadth index of 50% or more; and B) a fill phase at leastpartially filling pores in the matrix phase, wherein the fill phasecomprises at least 30 wt % of the heterophasic propylene copolymercomposition, based on the total weight of the matrix and fill phases. 2.The process of claim 1, wherein the fill phase comprises 35 wt % or moreof the heterophasic propylene copolymer composition, based on the totalweight of the matrix and fill phases.
 3. The process of claim 1, whereinthe matrix phase has a melting point (Tm, DSC peak second melt) of atleast 100° C.
 4. The process of claim 1, wherein the matrix phase has amedian pore diameter less than 165 μm, as determined by mercuryintrusion porosimetry.
 5. The process claim 1, wherein the fill phasecomprises a polyolefin having a Tg of −20° C. or less determined by DSC.6. The process of claim 1, wherein the matrix phase has a multimodalmolecular weight distribution and an overall molecular weightdistribution of 5 or more.
 7. The process of claim 1, wherein the fillphase of component B) comprises ethylene and from about 3 wt % to 75 wt% of one or more C₃ to C₂₀ alpha olefins.
 8. The process of claim 1,wherein the fill phase of component B) has a CDBI of 50% or more.
 9. Theprocess of claim 1, wherein the heterophasic propylene copolymercomposition is particulated and at least 95% by volume of the particleshas a particle size greater than about 120 μm.
 10. The process of claim1, wherein the heterophasic propylene copolymer composition has: 1) atotal propylene content of at least 75 wt %; 2) a total co-monomercontent from about 3 wt % up to about 25 wt %; 3) a CDBI of at least60%; 4) a fill phase content of 35 wt % or more, based on the totalweight of the matrix and fill phases; 5) a matrix median pore diametergreater than 6 μm and less than 160 μm, as determined by mercuryintrusion porosimetry; 6) at least 50% isotactic pentads; 7) more than10 regio defects per 10,000 propylene units, determined by ¹³C NMR; 8) a1% Secant flexural modulus of greater than about 300 MPa; 9) a matrixphase having a melting point (Tm, DSC peak second melt) of at least 120°C.; 10) a fill phase having a Tg of −30° C. or less determined by DSC;11) a heat of fusion (Hf, DSC second heat) of 60 J/g or more; 12) atleast 95% by volume having a particle size greater than 150 μm up to 10mm; 13) a melt flow rate (MFR, ASTM 1238, 230° C., 2.16 kg) from about0.1 dg/min up to about 300 dg/min; and 14) an Mw (as measured byGPC-DRI) from 50,000 to 1,000,000 g/mol.
 11. A process forpolymerization of propylene and a comonomer, comprising: (a) contactingpropylene monomer under polymerization conditions with a first catalystsystem, comprising a single site catalyst precursor compound, anactivator, and a support having an average particle size of more than 30microns, a surface area of 400 m²/g or more, a pore volume of from 0.5to 2 mL/g, and a mean pore diameter of from 1 to 20 nm (10 to 200angstroms) as determined by BET nitrogen adsorption, to form a matrixphase of propylene polymer comprising at least 50 mol % propylene andhaving a porosity of 15% or more as determined by mercury intrusionporosimetry; and (b) contacting an alpha olefin monomer selected fromethylene, C₃ to C₂₀ alpha olefins, or a combination thereof, includingat least one alpha olefin other than propylene, with a second catalystsystem under polymerization conditions to form a fill phase for thepores of the matrix, wherein the second catalyst system comprises ametallocene catalyst precursor compound, an activator, and a support,and wherein the second catalyst system comprises, compositionally, thesame or different single site catalyst precursor compound as in thefirst catalyst system, the same or different activator as in the firstcatalyst system, the same or different support as in the first catalystsystem, or any combination thereof.
 12. The process of claim 11, wherein(1) the polymerization of the alpha olefin monomer in (b) is in thepresence of the matrix phase from (a), (2) the polymerization of thepropylene monomer with the first catalyst system in (a) is in thepresence of the fill phase from (b), or (3) a combination thereof. 13.The process of claim 11, wherein the contacting in (a) comprisespolymerizing the propylene monomer for a time period, A1, optionallyincreasing a concentration of hydrogen or other chain termination agentin the polymerization after time period A1 and polymerizing thepropylene in the presence of the hydrogen or other chain transfer agentfor a time period, A2, wherein a time period A equals the sum of timeperiods A1 and A2, and the contacting in (b) comprises polymerizing thealpha olefin monomer for a time period, B, after time period A.
 14. Theprocess of claim 13, wherein time period A2 is greater than zero,wherein time period A1 is at least as long as time period A2, andwherein the concentration of the hydrogen or other chain transfer agentduring time period A2 is at least three times greater than theconcentration of the hydrogen or other chain transfer agent in timeperiod A1.
 15. The process of claim 13, wherein the support of the firstcatalyst system has an average particle size of more than 50 μm, asurface area of less than 1000 m²/g, or a combination thereof.
 16. Theprocess of claim 13, wherein the specific surface area of the support ofthe first catalyst system is more than 650 m²/g and the mean porediameter is less than 7 nm (70 Å).
 17. The process of claim 16, whereinthe first catalyst system has a bimodal particle size distribution,wherein a larger one of the first catalyst system modes comprises atleast about 80 vol % and a smaller one of the catalyst system modescomprises at least about 5 vol %, based on the total volume of the firstcatalyst system.
 18. The process of claim 13, wherein the specificsurface area of the support of the first catalyst system is less than650 m²/g, the mean pore diameter is greater than 7 nm (70 Å), or both.19. The process of claim 13, wherein the support of the first catalystsystem comprises agglomerates of primary particles, and the secondcatalyst system comprises fragments from the first catalyst system. 20.The process of claim 13, wherein the alpha olefin monomer comprisesethylene and from about 3 wt % to 75 wt % of one or more C₃ to C₂₀ alphaolefins.
 21. The process of claim 13, wherein the propylene monomer in(a) is essentially free of ethylene and C₄ to C₂₀ alpha olefins, and thepropylene polymer formed after time period A is a propylene homopolymer.22. The process of claim 13, wherein the activator of the first catalystsystem comprises alumoxane.
 23. The process of claim 13, wherein thefirst catalyst system further comprises a co-activator selected from thegroup consisting of: trialkylaluminum, dialkylmagnesium, alkylmagnesiumhalide, and dialkylzinc.
 24. The process of claim 13, wherein thecontacting of the propylene monomer with the first catalyst systemduring time period A1, time period A2, or the contacting of the alphaolefin monomer with the second catalyst system during time period B, ora combination thereof, are carried out in the liquid slurry phase. 25.The process of claim 13, wherein the polymerization conditions duringtime periods A1, A2, and B comprise a pressure of from about 0.96 MPa(140 psi) to about 5.2 MPa (750 psi) and a temperature of from about 50°C. to 100° C.